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I denna rapport med titeln Lean production system-Implementering av produktionssystem samt dess hinder utifrån ett organisatoriskt perspektiv, granskas kategorierna organisationsteori och Lean production system inom ramen för rapportens studie av ett fordonstillverkande företag. Specifikt ligger fokus på organisationskulturer, konflikter och motivationsteorier, men även utvecklings- och förbättringsprocesser, olika typer av slöserier som frekvent dyker upp och ledarskap ägnas uppmärksamhet med avseende på att skapa en djupare förståelse för hur en befintlig organisationskultur påverkas vid implementering av Lean production system och hur slöserier kan uppstå.   En av rapportens intentioner är att beskriva och analysera varför organisationer som implementerar och genomför Lean production system och integrerar detta i det egna produktionssystemet, kan uppleva svårigheter och medverka till att organisationer inte uppnår sina fulla potentialer. Föreliggande rapport använder som exempel i denna framställning företaget Volvo Cars i Göteborg som kategoriseras som en Lean hybrid. En Lean hybrid är företag som implementerat Lean production system med sitt egna produktionssystem och följer de principer Lean production system förespråkar. En viktig aspekt som underbygger syftet är att kunna beskriva de konsekvenser som sannolikt blir följden då organisationer inte anpassar strukturerna i sina produktionssystem efter vad Lean production system förespråkar om gällande förbättringsarbeten och arbetet mot att eliminera slöserier. Omvänt innebär detta att om befintliga produktionssystemen följer vissa principer och premisser, ska de verktyg och metoder som Lean production system erbjuder, vara giltiga och effektiva i målet att förbättra och förenkla  Syftet med rapporten var att undersöka varför organisationer med befintliga produktionssystem stöter på hinder och problem med att implementera och genomföra Lean production system i sina organisationer, samt hur stort inflytande organisationskultur och förhållningssätt har i denna process.  Rapportens metodansats utgörs av kvalitativa och kvantitativa metoder med tyngdpunkt på kvalitativ metod. En litteraturstudie har genomförts via de databaser som högskolan erbjuder. Insamling av data har skett genom observation, intervjuer och simuleringar för att få ett helhetsperspektiv på nuläget i Volvo Cars i Göteborg.   Rapportens resultat visar att en specifik organisationskultur kan medverka till att produktionsnedsättande faktorer som slöserier, tröghet i information och instruktion flödet, subkulturer, konflikter och bristande motivation skapas eller fortsätter att existera, men pekar också på vikten av att en organisationskulturs policy bör gestaltas på alla nivåer i en organisationsstruk- 2 -  tur. Problem och hinder kan således skapas och uppstå när det saknas en gemensam värdegrund för ledarskap, utbildning och kompetensutveckling. En konsekvens av detta är att produktionsnedsättande faktorer tenderar att bäddas in i redan befintliga och standardiserade rutiner, där förbättringsarbeten paradoxalt nog skapar en negativ utveckling av produktionsprocesser och med tiden utvecklas till typ-II slöserier. / In this report entitled Lean production system- Implementation of Lean as well as its obstacles from an organizational perspective, the categories of organization theory and Lean production system are examined in the context of the report's study of a vehicle-making company. Specifically, the focus is on organizational cultures, conflicts and motivational theories, but also development and improvement processes, different types of waste and leadership. Attention is given to creating a deeper understanding of how an existing organizational culture is influenced by implementation of Lean production systems and how wastes can occur.  One of the intentions of the report is to describe and analyze why organizations that implement and carry out Lean production systems and integrate this into their own production system can experience difficulties and help organizations not achieve their full potentials. The present report uses, for example, in this study the company Volvo Cars in Gothenburg, categorized as a Lean hybrid. A Lean hybrid is a company that implemented Lean production system with its own production system and adheres to the principles lean pro duction system advocates. An important aspect that underpins the purpose isto be able to describe the consequences that are likely to be followed when organizations do not adapt the structures in their production systems according to the Lean production system and what it advocates on continuous improvement efforts and efforts to eliminate waste. Conversely, this means that if existing production systems following certain principles and premises, the tools and methods provided by the Lean production system should be valid and effective in the goal of improving and simplifying.  The purpose of the report was to investigate why organizations with existing production systems encounter obstacles and problems in implementing and carrying through Lean production systems in their organizations, as well as the influence of organizational culture and approaches in this process.   The method of assessment of the report consists of qualitative and quantitative methods with a focus on qualitative methodology. A literature study has been conducted through the databases offered by the university. Data collection has been through observation, interviews and simulations to get a full-view perspective at the current moment in Volvo Cars in Gothenburg.  The report's results show that a specific organizational culture can contribute to the creation or continuation of production-reducing factors such as waste, inertia in information & instruction flow, subcultures, conflicts and lack of motivation. However, it also emphasizes the importance of organizational culture policy being embodied at all levels in an organizational structure. Problems and obstacles can thus be created and arise when there is no common value base for leadership, education and competence development. One consequence of this is that production-lowering factors tend to be embedded in existing and standardized practices, where improvement efforts paradoxically create a negative development of production processes and eventually develop into Type II wastes.

This thesis examines barriers to the implementation of Lean production systems in China. The aim is to evaluate how implementation barriers affect a Lean production system, and whether they can be explained by Chinese national context factors. The thesis also aims to investigate the mechanisms by which such context factors influence the barriers. A socio-technical systems (STS) perspective is taken to interpret the relative importance of, and the interplay between, the social and the technical barriers to Lean implementation in China. To achieve the aims of the study, a multiple case study approach was chosen. I collected data at two Chinese plants of a globally-operating German automotive supplier in Suzhou and Changsha. As the main method of data collection, I conducted sixty qualitative interviews with Chinese and Western employees during a two month research trip to China. Using an iterative procedure of data collection and analysis, I developed a model that captures barriers to implementing Lean in China, the effects of these barriers on the production system, and influential context factors. Based on respondents perceptions, I identify six main implementation barriers, namely: High employee turnover , Weak supplier performance , Market conditions , Lack of Lean knowledge , Intercultural communication , and Work styles . The analysis highlights the effects of the barriers on specific elements of the Lean production system, and mechanisms by which the context factors influence the barriers. By exploring these mechanisms, I found strong evidence that Chinese context factors act as root causes or catalysts for the implementation barriers. The findings are corroborated through a comparison of the results obtained from the two locations in China, reports by Western and Chinese employees, and respondents at different hierarchical levels of the organisation. Through the Lean implementation model, this research contributes to the literatures on international Lean manufacturing and socio-technical systems. The study is the first to provide detailed empirical evidence of six main barriers, and to describe thoroughly why each barrier was a burden for Lean. The thesis also contributes to the Lean literature by demonstrating how the national context of China can create barriers and therefore play a significant role when implementing Lean in China. The central claim of the study is therefore that implementation barriers do exist in China and that a greater focus on these barriers is required in order to gain a better understanding of Lean implementation in this context. With regard to STS theory, the study highlights that the main perceived barriers to Lean implementation were situated within the social sub-system of Lean, and that some aspects of the barriers were created through a lack of joint optimisation of the social and the technical sub-system. The study therefore shows that STS theory is applicable to the context of Lean systems, and that it facilitates our understanding of barriers to the socio-technical Lean system. The study yields recommendations on managerial strategies for implementing Lean production in China, regarding people management as well as the adjustment of manufacturing facilities. A consideration of the national context can help practitioners to fully understand the causes of implementation barriers in China and, through this, to overcome these barriers. The thesis is concluded by reflecting on its limitations and suggestions for future research.

Submitted by Aelson Maciera (aelsoncm@terra.com.br) on 2017-06-26T17:43:11Z No. of bitstreams: 1 TeseLLLN.pdf: 5979682 bytes, checksum: 33c85f24ff1e44060833272e3c346492 (MD5) / Approved for entry into archive by Ronildo Prado (ronisp@ufscar.br) on 2017-06-28T19:50:12Z (GMT) No. of bitstreams: 1 TeseLLLN.pdf: 5979682 bytes, checksum: 33c85f24ff1e44060833272e3c346492 (MD5) / Approved for entry into archive by Ronildo Prado (ronisp@ufscar.br) on 2017-06-28T19:50:19Z (GMT) No. of bitstreams: 1 TeseLLLN.pdf: 5979682 bytes, checksum: 33c85f24ff1e44060833272e3c346492 (MD5) / Made available in DSpace on 2017-06-28T19:56:12Z (GMT). No. of bitstreams: 1 TeseLLLN.pdf: 5979682 bytes, checksum: 33c85f24ff1e44060833272e3c346492 (MD5) Previous issue date: 2016-12-13 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / The objectives of this thesis were to identify the path of implementation of lean practices in the manufacturing industry located in a region of scarce resources from a developing country, to evaluate the insertion degree such means according certain control variables (company size, industrial sector and the main productive typology) as well as to evaluate the effects of the lean manufacturing implementation on the performance of the companies studied. By means of a Survey, it was possible to investigate the lean manufacturing implementation using robust statistical techniques to define the measurement model defined as the mean of lean manufacturing adoption by the industry researched and to evaluate the effect of such adoption on performance. The results show a high, but partial, degree of lean adoption, which is observed by the identification of its implementation path composed of six internal practices (Single-Minute Exchange of Dies, Human Resource Management, Continuous Flow, Total Productive Maintenance, and Statistical Process Control) and two external (Supplier feedback and Customer engagement). Two other important lean practices (Just In Time delivery and Supplier development) have not been implemented, probably due to the region and country characteristics in where the companies are located such as: remote suppliers and lack of transport/logistics infrastructure plus the great territorial extension. In addition, such adoption has occurred in a fragmented way, as from 36 operational measures that comprise the eight practices considered as the lean implementation path, 13 have not been implemented. Moreover, it was verified the degree of adoption of the lean practices changes according to the company’s size (bigger companies tend to incorporate more practices compared to smaller companies) and the industrial sector. However, there has been no variation in the degree of adoption considering the main productive typology. Finally, it was observed the Lean Manufacturing interrelationship model has a positive effect on operational, financial and environmental performances. / Os objetivos desta tese foram identificar o caminho de implementação de práticas Lean na indústria manufatureira localizada em uma região de recursos escassos de um país em desenvolvimento, avaliar o grau de adoção de tais práticas conforme determinadas variáveis de controle (tamanho da empresa, setor industrial e tipologia produtiva principal) e avaliar o efeito da implementação de Lean Manufacturing no desempenho das empresas pesquisadas. Por meio de um Survey, foi possível investigar a implementação da manufatura enxuta com o uso de técnicas estatísticas robustas para definição do modelo de mensuração estabelecido como o caminho de adoção da manufatura enxuta pela indústria pesquisada e avaliar o efeito de tal adoção no desempenho empresarial. Os resultados mostram um elevado grau de adoção do Lean, porém de forma parcial, evidenciada pela identificação do seu caminho de implementação, composto por seis práticas internas (troca rápida de ferramentas, gestão de recursos humanos, fluxo contínuo, manutenção produtiva total, processo puxado e controle estatístico do processo) e duas externas (feedback de fornecedor e envolvimento de cliente). Além disso, duas importantes práticas Lean (fornecimento Just In Time e desenvolvimento de fornecedores) não vem sendo implementadas, provavelmente em função das características da região do país onde as empresas estão inseridas, a saber: fornecedores distantes e falta de infraestrutura de transporte/logística somada a grande extensão territorial da região estudada. Além disso, tal implementação tem ocorrido de forma fragmentada, visto que dentre as 36 medidas operacionais que compreendem as oito práticas consideradas como o caminho de implantação do Lean, 13 não foram implementadas. Verificou-se também que o grau de adoção das práticas Lean muda conforme o tamanho das empresas (empresas maiores tendem a implementar mais práticas comparada às empresas menores) e o setor industrial. Entretanto, não houve variação no grau de adoção conforme a tipologia produtiva principal. Por fim, observou-se que o modelo estrutural de inter-relação de Lean Manufacturing, apresenta efeito positivo sobre o desempenho empresarial nos âmbitos operacional, financeiro e ambiental.

Made available in DSpace on 2015-04-22T22:11:22Z (GMT). No. of bitstreams: 1 Alberjan.pdf: 1648406 bytes, checksum: e7cc01faadea0adae547a7958b75ccce (MD5) Previous issue date: 2011-07-15 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / This work was aimed at applying the tools of the PRS System (Lean Production), whose primary tool was crafted VSM (Value Stream Mapping), a process known as SMT (Surface Mount Technology). Principles for lean production, eliminating waste and creating value stream in a real situation through kaizen events, were used to obtain results of this application, showing a lean transformation, with significant reductions in waste generated in the process. The study period was eight months into a private company located in PIM, where through the use of tools of this system and methodology of action research, it was possible to identify the critical process - setup - where focused improvement actions. With the change in the system setup, the standard work and creating a setup program using visual aid, favoring the continuous flow in this process. During the research, trainings were conducted in the factory with the operators, leaders, supervisors and engineers responsible, who participated actively in the improvement actions. Therefore, through value stream mapping, we propose to draw the current state of the stream, offering a future state, identifying and eliminating everything does not add value. To quantify the increase in productivity on the factory floor and total earnings of areas in the factory. / Este trabalho teve como objetivo a aplicação das ferramentas do Sistema de Produção Enxuta (SPE), cuja principal ferramenta trabalhada foi o Mapeamento da cadeia de valor (VSM), num processo denominado Tecnologia em Montagem de Superfície (SMT). Princípios que regem a produção enxuta, eliminação de desperdícios e a criação do fluxo de valor em uma situação real, através de eventos kaizen, foram utilizados para a obtenção de resultados dessa aplicação, evidenciando uma transformação enxuta, com expressivas reduções dos desperdícios gerados no processo. O período da pesquisa foi de oito meses em uma empresa privada situada no PIM, onde por meio da utilização de ferramentas desse sistema e a metodologia da pesquisa-ação, foi possível identificar o processo crítico setup para onde se concentraram as ações de melhorias. Com a mudança na sistemática de setup, no trabalho padronizado e criação de um setup programado, utilizando indicações visuais, favorecendo o fluxo contínuo nesta cadeia produtiva. No desenvolvimento da pesquisa, foram realizados treinamentos in loco com os operadores, líderes, supervisores e os engenheiros responsáveis, os quais participavam ativamente nas ações de melhoria. Portanto, através do mapeamento da cadeia de valor, propõem-se desenhar o estado atual da cadeia, propondo um estado futuro, identificando e eliminando aquilo que não agrega valor. Com isso, quantificar o aumento na produtividade no chão de fábrica e ganhos totais de áreas na fábrica.

六標準差（Six Sigma）為目前最受矚目與重視的品質活動，而精實生產方式（Lean Production System）係以及時化（Just-In-Time, JIT）及自働化（Jidohka）兩大概念，所發展出來的合理化生產系統。此二者俱以變異為基礎的思考（Variation-based Thinking），協助企業改善流程、提昇品質、生產力與競爭地位，其整合並被視為下一波管理思潮的新趨勢。 此外，若論及產業特性，服務產業有別於製造業，其特有的服務（Service）、交易業務（Transaction）與其他非製造性（Non-Manufacturing）流程，往往存在更多浪費與更多的改善機會，卻更為強調顧客滿意經營。 本研究鑑於研究缺口與實務發展之需，提出六標準差與精實生產方式應用於服務業之整合模式（Lean Six Sigma for Service，LS3）。本模式以精實生產方式減少內部浪費，並以六標準差導向顧客滿意之追求，不但兼顧企業內部與外部顧客之觀點，亦兼顧精實速度與六標準差之高品質。 / “Six Sigma” is one of the most popular quality initiatives recently. “Lean Production System” is the world famous production system developed and practiced by Toyota mobile company for a long time. It based on two concepts: “Just-In-Time” and “Jidohka”. Both two are based on the variation thinking to improve business process, enhance quality, production and competitive position. Besides, the integration of them is viewed as a new trend in the next management wave. Moreover, regarding to the industry characteristics, service industry is quite different from manufacturing industry. Even though there are more wastes and improvement opportunities, the application of Six Sigma, Lean Production System or their integration in service industry is quite few neither in literatures nor practice. This research proposes the Lean Six Sigma integration model based on the research gap and the practical need, and then adapt it for service industry. The model is named as “Lean Six Sigma for Service (LS3)” in this research. It balances the viewpoints of internal and external customers, and gives consideration to the Lean speed as well as Six Sigma high quality. Also, this research tries to contribute to the enhancement of management technology. / 目 錄 中文摘要………………………………………………………………………………I 英文摘要………………………………………………………………………………Ⅱ 誌謝……………………………………………………………………………………Ⅲ 目錄……………………………………………………………………………………Ⅳ 表目錄…………………………………………………………………………………Ⅶ 圖目錄…………………………………………………………………………………Ⅷ 第一章 緒 論…………………………………………………………………………1 1.1 研究背景與動機………………………………………………………………1 1.2 研究目的………………………………………………………………………4 1.3 研究範圍與限制………………………………………………………………5 1.4 研究方法………………………………………………………………………6 1.5 研究架構………………………………………………………………………7 第二章 文獻探討…………………………………………………………………8 2.1 六標準差………………………………………………………………………8 2.1.1 六標準差之發展沿革………………………………………………………8 2.1.2六標準差之定義與各家說法………………………………………………12 2.1.3 六標準差之組織架構及人員角色…………………………………………17 2.1.4 六標準差之改進循環………………………………………………………21 2.1.5 六標準差主要之八大工具…………………………………………………27 2.1.6 六標準差之推行現況………………………………………………………29 2.1.7 六標準差之運作特點………………………………………………………30 2.2 精實生產方式…………………………………………………………………31 2.2.1 精實生產方式之發展沿革………………………………………………31 2.2.2精實生產方式之定義…………………………………………………….34 2.2.3 精實生產方式之構成要素………………………………………………34 2.2.4 精實生產方式之推展步驟………………………………………………40 2.2.5 精實生產方式之運作特點………………………………………………42 2.3服務業…………………………………………………………………………46 2.3.1 服務業之定義……………………………………………………………46 2.3.2 服務業之特性……………………………………………………………48 第三章 模式建構…………………………………………………………………52 3.1 精實六標準差應用於服務業之綜觀（LS3 Overview）……………………52 3.2 導引階段（Lead Phase）……………………………………………………………56 3.3 研究階段（Study Phase）……………………………………………………………65 3.4 流暢階段（Smooth Phase）…………………………………………………………70 3.5 維持階段（Sustain Phase）…………………………………………………………73 第四章 模式驗證.…………………………………………………………………81 4.1 問卷對象…….………………………………………………………………81 4.2 專家意見…….………………………………………………………………83 第五章 結論與建議…………………………………………………………………84 5.1 研究結論……………………………………………………………………84 5.2 研究貢獻……………………………………………………………………85 5.3 後續研究建議………………………………………………………………86 參考文獻……………………………………………………………………………87 附錄A 專家訪談調查函……………………………………………………………93 附錄B 專家訪談問卷內容…………………………………………………………94 表 目 錄 表 2.1 六標準差的發展階段………………………………………………………12 表 2.2 標準差換算表………………………………………………………………14 表 2.3 六標準差方法論DMAIC………………………………………………………22 表 2.4 六標準差設計方法論DMADV……….………………………………………23 表 2.5 六標準差「工具的21個整合步驟：研發流程」…………………………25 表 2.6 豐田生產系統之「實驗」……………………………………………………44 表 3.1 LS3之內容要項與工具……………………………………………………54 圖 目 錄 圖 1.1 研究流程圖………………………………………………………………6 圖 2.1 製程中心飄移1.5標準差的情形………………………………………13 圖 2.2 典型的六標準差組織圖.…………………………………………………17 圖 2.3 執行六標準差之八大步驟…….…………………………………………27 圖 2.4 六標準差之八大工具…..…………………………………………………28 圖 2.5 精實生產方式五大主要要素…….………………………………………36 圖 2.6 消除浪費要素……………………………………………………………37 圖 2.7 全面品質要素………………………………………………………………38 圖 2.8 人員準備要素………………………………………………………………39 圖 3.1 LS3運作架構圖………………………………………………………………53 圖 3.2 LS3運作模式之工具總覽……………………………………………………55 圖 3.3 導引階段之使用工具………………………………………………………57 圖 3.4 研究階段之使用工具………………………………………………………66 圖 3.5 流暢階段之使用工具………………………………………………………70 圖 3.6 維持階段之使用工具………………………………………………………74

The design process of a production system referred to as the production system design process (PSDP) impacts on the operational performancethroughout the lifecycle of the production system, especially on the rampupand operation phases. Despite the impact of activities of PSDP on the operational performance, how to manage the PSDP is still a challenge for manufacturing companies. Earlier research urged to develop a systematic PSDP concerning its impact on the operational performance. This thesis aims to contribute with knowledge of how manufacturingcompanies can manage the PSDP by investigating 1) the enablers in thePSDP that impact on operational performance in ramp-up and operation phases, and 2) how the lean production concept could be adopted tomanage the activities during the PSDP. A case study was conducted in aprocess type manufacturing company, where empirical data were collectedfrom three new production line launching projects by qualitative means. This thesis identifies a set of enablers in the PSDP that potentiallyimpact the operational performance after launching the productionsystem. Empirical findings demonstrate that ensuring proper actions onthe identified enablers in the PSDP could lead to higher operationalperformance of the designed production system. These enablers rangefrom the company´s internal boundary to external vendors, requiring asystematic way to manage these diverse aspects. Adopting the lean production concept in the PSDP context, this thesis proposes a model of Lean Production System Design Process, containing 13 principles andrelevant practices. The proposed model of lean PSDP could be used as a systematic processto manage the activities in the PSDP that would ensure proper actions related to the identified enablers. Empirical findings indicate that adoptionof lean in the PSDP could result in reducing lead time of launching a new production system, and achieving fast ramp-up and desired operational performance considering sustainability aspects. Finally, this thesis demonstrates how the lean PSDP could be a means to achieve a sustainable competitive advantage based on the resource based view theoretical perspective. / Utformningsprocessen av ett produktionssystem, i denna avhandlingkallad produktionssystemets utformningsprocess (PSUP), påverkar denoperativa prestandan under hela produktionssystemets livscykel, särskilt iupprampnings- och driftsfasen. Traditionellt sett ligger fokus underutformningsprocessen på att lansera det nya produktionssystemet vidplanerad tidpunkt och enligt budget. Trots att de aktiviteter somgenomförs i utformningsprocessen påverkar den operativa prestandan idriftsfasen, ägnas ofta mindre uppmärksamhet åt designfasen än vad somvore önskvärt. Tidigare forskning har argumenterat för att utveckla ensystematisk designprocess för framtagning av produktionssystem medsyfte att nå en positiv påverkan på den operativa prestandan. Forskningen i denna avhandling bidrar till att öka kunskapen om hurPSUP kan hanteras och förbättras genom att identifiera: 1) möjliggörare i PSUP som påverkar den operativa prestandan i upprampnings- ochdriftfasen, och 2) hur lean konceptet skulle kunna användas för att hanteraaktiviteterna under PSUP. Resultatet är identifieringen av ett antal faktorer/möjliggörare iproduktionssystemets utformningsprocess (PSUP) som potentiellt kanpåverka den operativa prestandan efter lansering av produktionssystemetoch produktionsstart. Dessa möjliggörare handlar om alltifrån frånföretagets interna gränser till externa leverantörer och kräver ensystematisk procedur för att dra nytta av faktorernas potential. Genom attanvända lean även i PSUP-sammanhanget, föreslås här konceptet Lean PSUP (produktionssystemsutformningsprocess), som innehåller 13 principer och relevanta praxis. Den föreslagna modellen för lean PSUP skulle kunna användas och gestruktur till hanteringen av aktiviteterna i utformningsprocessen.Forskningen indikerar att lean inte bara kan användas i driftsfasen utanäven i utformningen av ett produktionssystem, vilket skulle kunnaresultera i bättre integration mellan olika funktioner, minska ledtiden förutformning och lansering av ett nytt produktionssystem, och uppnå snabbupprampning och önskad operativ prestanda, både avseende produktionoch hållbarhet. Slutligen visar denna avhandling hur lean PSUP kan varaett sätt att uppnå konkurrensfördelar ur ett resursbaserat teoretiskt perspektiv.