Made available in DSpace on 2014-06-11T19:30:09Z (GMT). No. of bitstreams: 0 Previous issue date: 2008-06-20Bitstream added on 2014-06-13T20:39:46Z : No. of bitstreams: 1 fernandes_st_me_guara.pdf: 826161 bytes, checksum: 1d2c98dc42fcc4f9ab290957112eccca (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / Este trabalho apresenta a aplicação do Lean Six Sigma em um estudo de caso na indústria metalúrgica. O Six Sigma e o Lean Manufacturing são dois processos de melhoria utilizados por diversas empresas. Atualmente, a integração destes processos é um desafio para estas empresas, que buscam uma maneira mais eficiente de reduzir seus desperdícios e se adaptarem às necessidades de seus mercados consumidores. O trabalho teve como finalidade demonstrar a aplicabilidade do Lean Six Sigma em um problema logístico real de transporte de produtos entre as unidades de uma indústria metalúrgica. As etapas usadas para a solução do problema seguem o ciclo DMAIC – Definir, Medir, Analisar, Melhorar e Controlar. A dissertação apresenta detalhadamente a abordagem integrada dos processos de melhoria Lean Manufacturing e Six Sigma, seus conjuntos de ferramentas, bem como os resultados obtidos no estudo de caso. / This work presents the application of Lean Six Sigma in a case study of the metallurgic industry. The Six Sigma and the Lean Manufacturing are two processes of improvement used by many enterprises. Currently the integration of these processes is a challenge for these companies, which search a way more efficient to reduce their wastes and to adapt to the needs of their markets. The work had as purpose to demonstrate the applicability of the Lean Six Sigma in a real logistical problem of the transportation of goods among units of the metallurgic industry. The stages used for the solution of the problem follow the DMAIC cycle – Define, Measure, Analyze, Improve and Control. The dissertation presents in details the integrated approach of the improvement processes Lean Manufacturing and Six Sigma, their tools set, as well the results obtained in the case study.

O Lean Six Sigma é a metodologia originada a partir da integração das metodologias Lean e Six Sigma. O Lean Six Sigma procura eliminar as perdas e reduzir os defeitos, agregando os benefícios de cada uma das duas metodologias que a dão origem. O objetivo deste trabalho é aplicar a metodologia Lean Six Sigma para melhoria de um processo produtivo. Neste trabalho é apresentada uma revisão bibliográfica sobre as metodologias Lean e Six Sigma, buscando a compreensão das origens do Lean Six Sigma, e uma revisão sobre a metodologia Lean Six Sigma. Baseado na revisão bibliográfica é apresentada uma metodologia para aplicação do Lean Six Sigma, que tem por estrutura o DMAIC (Define, Measure, Analyze, Improve and Control). Na sequência esta metodologia é aplicada para melhoria de um processo produtivo. Os resultados da aplicação do Lean Six Sigma foram: aumento do nível de sigma e redução dos defeitos do processo, demonstrando que as metodologias Lean e Seis Sigma podem ser integradas, e como ocorre essa integração. Os fatores de sucesso da aplicação da metodologia Lean Six Sigma também foram evidenciados. / Lean Six Sigma is a methodology originated from the integration of Lean and Six Sigma. Lean Six Sigma seeks for eliminate waste and reduce defects, combining benefits from both methodologies. The objective of this dissertation is apply the Lean Six Sigma methodology to improve a production process. In this dissertation is presented a bibliography review about the Lean and Six Sigma methodology, looking for understanding of the Lean Six Sigma sources and a review about the Lean Six Sigma methodology. Based on the bibliography review is presented a methodology to apply Lean Six Sigma, that has the DMAIC as the structure (Define, Measure, Analyze, Improve and Control). This methodology is applied to improve a production process. The results of the Lean Six Sigma application were the increase of sigma level and reduction of process defects, showing that Lean and Six Sigma can be combined and how this combination happens. The success factors of the application of Lean Six Sigma methodology were evidenced.

This diploma thesis has been created based on the demand of the management of DHL Exel Supply Chain and Swindon Pressings Limited to increase the efficiency and utilization of resources employed within they operations. The theoretical introduction part is first of dealing with the terms "logistics" and "supply chain management" in the perspective of their use in the contemporary logistics theory, comparison of their meaning (are there differences) and explanation of their use in this thesis. Subsequently I am explaining "reverse logistic" and its position in the structures of corporations and logistics itself. Supply chain management and the concept of lean manufacturing combined with the six sigma approach are, from my point of view, essential for today's supplier-customer relationships. That is why those topics are examined in the last part of the theoretical chapter. Returnable packaging and the transport process are key elements of the second part -- practical part, the reengineering of logistics processes which occurred at Swindon Pressings Limited. The aim of this thesis is to analyze the give problem, develop problem solving options and critically comment them. Finally choose one of the options, implement it and document the process of "going live".

This thesis is focused on the proposal form filling error rate in life insurance. The theoretical part of the thesis describes main aspects of the methodology Lean Six Sigma, which will be used to decrease high error rate. Lean Six Sigma is widely used in today's companies to improve business processes by increasing their sigma. The methodology is an integration of two separate approaches, both invented in the beginning of the 20th century. The aim of the integration is to bring together the best of both of them. The practical part of the thesis shows how the seemingly separed approaches Lean and Six Sigma can work together. Lean was used to improve the process for insurance company's sales force, and Six Sigma was then applied to decrease the error rate of the forms. Both of the improvements were successfully implemented in the company and led to a desired outcome.

Lean Six Sigma is one of the tools organizations use to help their processes run faster and thus maximize their profits. It is a thorough approach that can reveal defects in companies' processes through examining customers' needs and its statistical data Its popularity spreads fast from the early adopters such as General Electric, Toyota or Motorola and many companies are keen to get their hands on it and achieve similar success as above mentioned. Czech companies are not different. There is, however, a tendency to lay it aside based on first time impressions. The most frequent reasons are: complexity, need to make dramatic changes in the company's culture and high initial costs. Main goal of this thesis is to show that Lean Six Sigma does not necessarily have to be a thorough approach. It can also be used as a one-time tool to improve company's processes, just by picking the right parts and combining them in the right order. This thesis describes the most useful tools and also shows how they can be used in the real situation. By aligning them in a row it also creates a framework for Lean Six Sigma implementation projects which can be used repeatedly. One chapter also describes various problems that might occur during the implementation and provides readers with possible solutions to overcome them.

Diplomová práce se zabývá analýzou využití projektové metodologie Lean Six Sigma na finančním oddělení ve vybrané mezinárodní společnosti a návrhem postupu na jeho zlepšení. Jsou zde obsaženy teoretické poznatky týkající se metody Lean Six Sigma jako i praktická ukázka použití dané metody v praxi. Na základě údajů a zkoumání použití metody je provedená analýza efektivního využití. Následně je popsané zhodnocení dané analýzy a navržen postup pro zlepšení situace do budoucna.

The diploma thesis deals with the possibilities of making the process of realization of the multipurpose process more efficient, in the sense of dismantling of defective parts and return of the perfect parts back to the production process in the automo-tive industry. In the theoretical part of the diploma thesis there are laws and norms related to the automotive industry, including the applied methods in this industry with real researches in many companies all over the world. The following section introduces XYZ and its products. Follows the current process of disman-tling defective parts, Paret analysis with the Lean Six Sigma method. On the basis of analyzes and methods for streamlining the training workplace, one of the options for streamlining the process of implementation of the multi-site training at the XYZ training workplace.

This report presents an explorative examination of the scientific literature regarding current methods utilized in mixed-model assembly lines and the challenges that are faced. Empirical data from a real mixed-model assembly line was collected and analyzed to explore the application of the identified methods and the problems that are faced in a realistic situation.  The report consists of a theoretic framework on the topics of assembly systems and topics relevant to managing the challenges. In addition a case study is conducted where an assembly system is observed and real production data is collected. Product assembly lines make up one of the final steps in the manufacturing process of a product. By implementing proven methods for process improvements highly effective assembly lines are realized. If an assembly line is experiencing reliability issues the probability of the company’s end-customers being directly affected is considerably increased.  Ensuring reliability in a mixed-model assembly line (MMAL) is an important task with an increasing level of difficulty given the current evolution of advanced technology. The resulting increase in product variety and complexity made possible increases the demands on the entire manufacturing process and the assembly line in particular. Added product variety and complexity poses an increased challenge from an automation perspective as well due to the limitations in flexibility inherited by industrial robots in comparison to a human operator. Many challenges in manufacturing and assembly processes stem from product development, increased variation between product models, and changes in production systems, due to the resulting increase in the complexity of the production processes (ElMaraghy ​​& ElMaraghy, 2016). Historically, a vast number of manufacturing companies have seen significant improvements in their product quality and productivity, leading to improved financial results as well as customer satisfaction by implementing process development methods such as Lean production, Six Sigma, or Lean Six Sigma.  Therefore, the purpose of this report is to explore assembly system reliability and complexity management. The scope of this report is restricted to focus on reliability in assembly systems from a quality perspective. Suggestions for improvements are biased towards Lean Six Sigma methods and complexity management as described in current literature with the consequence of potentially valid methods and solutions being excluded. The theoretical framework of this report is based on selected books and scientific articles on the topics of complexity, assembly systems, process development, and human performance in the context of assembly systems.  The case study project is executed following the DMAIC-process as per the L6S methodology. Lean six sigma methodologies are applied in accordance with the selected literature with the objective of identifying a potential strategy for mitigating the quality deficiencies observed in the company´s assembly processes. The research presented in this report follows the abductive reasoning concept (Säfsten & Gustavsson 2020). Abductive reasoning is initialized by a conclusion, which is followed up by constructing a theory based on literature, and finally analyzing empirical data to validate the constructed theory in the context given by the initial conclusion.  Additionally, a root cause analysis is conducted. The root cause analysis is initiated by constructing an Ishikawa diagram to categorize and identify possible causes of the identified errors. By systematically working through each of the categories the examined problem is look upon from different points of view, making for a comprehensive analysis. In this step the 5-why’s method is utilized to support the deductive reasoning process. The potential root causes are then utilized to construct a list of possible solutions and suggestions for improvement for the examined problem. The improvement suggestions are based on deductive reasoning as well as documented improvements from the literature.

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / In the arms industry, quality is essential because its products are used for special purposes. Therefore, in production, the rate of defective products is low. This study proposes a model to reduce the number of defective products based on the combined use of the Six Sigma and work method tools. For the purposes of this study, the production process of the 7.62 mm ammunition was analyzed because it presents several issues that affect product quality. The current methods and procedures of the production process were analyzed to identify the root causes of the problem and to provide a solution. After implementing the model, defective products were reduced from 20% to 13.67%..

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / Even though there is a high demand for clothing articles in the market, they do not meet quality standards. This can be appreciated after the clothes are washed and dried and the study revealed that over 20% of the items were returned each month. This occurs when the acquisition of raw materials is focused exclusively on the price. Thus, there are no requirements for compliance with any technical specifications that would enable the production process to be equipped with quality raw materials. Additionally, the absence of control over the quantity of consumables based on demand generates reprocessed inventory, thus damaging the fabric. Therefore, the proposed model was made through the Lean Six Sigma method to reduce waste and meet client requirements. The results were a decrease in returns by over 16.5% and an increase in productivity by 28.5%.