<p>The purpose of this thesis is to develop a model for assessing cost effectiveness of applying lean tools. The model consists of eight phases: it starts by understanding customers' requirements using Voice of Customer (VOC) and Quality Function Deployment (QFD) tools. In phase 2, the current state of plant is assessed using lean profile charts based on Balanced Scorecard (BSC) measures. In phase 3 and phase 4, identification of critical problem(s) and generating of improvement suggestion(s) are performed. Phase 5 provide evaluation of the cost effectiveness of implementing the suggested lean methods based on life cycle cost analysis (LCCA) and phase 6 prefers the right alternative based on multiple criteria decision making (MCDM). In phase 7 the selected alternative is supposed to be implemented and finally the user should monitor and control the process to make sure that the improvement is going as planned. The model was verified successfully using a case study methodology at one Swedish sawmill called Södra Timber in Ramkvilla, one part of Södra group. Results obtained from the study showed that the production and human resources perspectives are the most critical problem areas that need to be improved. They got the lowest scores in the lean profile, 63% and 68%, respectively. Using value stream mapping (VSM) it was found that the non value added (NVA) ratios for the core and side products are 87.4% and 90.4%, respectively. Using the model, three improvement alternatives were suggested and evaluated using LCCA and MCDM. Consequently, implementing 5S got the highest score, second came redesigning the facility layout. However, it was estimated that 4.7 % of NVA for the side product would be reduced by redesigning the facility layout. The recommendations were suggested for the company to improve their performance. The novelty of the thesis is based on the fact that it addresses two main issues related to lean manufacturing: firstly, suggesting lean techniques based on assessment of lean profile that is based on BSC and QFD, and secondly assessing the cost effectiveness of the suggested lean methods based on LCCA and MCDM. This thesis provides a generalized model that enables the decision-maker to know and measure, holistically, the company performance with respect to customer requirements. This will enable the company to analyze the critical problems, suggest solutions, evaluate them and make a cost effective decision. Thus, the company can improve its competitiveness.</p>

A competitividade de uma empresa é passível de ser construída em diferentes dimensões. Entre elas, está o modelo de gestão da produção. E, nesse sentido, destacam-se ferramentas do modelo lean. Esse modelo de produção tem sido o núcleo de numerosas iniciativas de melhoria contínua e referenciado como necessário para o aumento da competitividade das empresas. Contudo, ao considerarmos o universo das médias empresas e a implementação de um modelo de produção, realizado como um processo contínuo de melhoria, que permite estabelecer os objetivos e as capacidades da empresa, além de orientar à melhor utilização dos recursos, é pouco utilizado, e tais organizações se apresentam ineficientes na implementação de um modelo de produção que aumente sua competitividade. Partindo dessa proposição, uma empresa que adotou como modelo de gestão da produção o lean, deveria ter, também informação acerca dos benefícios das ferramentas implementadas, bem como o seu efeito sobre o desempenho produtivo. Nesse sentido, a proposta deste trabalho consiste em avaliar quais ferramentas do modelo lean foram implementadas em cinco médias empresas do segmento automotivo, em diferentes países, se houve benefícios para o processo produtivo em função da implementação e se as ferramentas foram implementadas baseadas em algum método estruturado ou não. / Submitted by Marcelo Teixeira (mvteixeira@ucs.br) on 2014-04-29T11:40:08Z No. of bitstreams: 1 Dissertacao Rubilar Toniazzo.pdf: 2713904 bytes, checksum: 503ebd1c9afeeaa97084a6d3d6c6636f (MD5) / Made available in DSpace on 2014-04-29T11:40:08Z (GMT). No. of bitstreams: 1 Dissertacao Rubilar Toniazzo.pdf: 2713904 bytes, checksum: 503ebd1c9afeeaa97084a6d3d6c6636f (MD5) / The competitiveness of a company is liable to be built in different dimensions. Among them, the model of production management. And in this sense we highlight the model lean tools. This production model has been the core of numerous continuous improvement initiatives and referenced as needed to increase the competitiveness of companies. However, when considering the universe of medium enterprises and a implementation of a production model, performed as a continuous process of improvement, which allows us to establish the goals and capabilities of the company, besides guiding the best use of resources, it is rarely used and such organizations present inefficient implementation of a production model that increases their competitiveness. From this proposition, a company that has adopted as a model of lean production management, should have the information about the contribution of the tools implemented, as well as its effect on performance. In this sense, the purpose of this study is to assess which model lean tools were implemented in five medium-sized companies from the automotive sector, in different countries, there are benefits to the production process due to the implementation and tools have been implemented based on a structured method or not.

A competitividade de uma empresa é passível de ser construída em diferentes dimensões. Entre elas, está o modelo de gestão da produção. E, nesse sentido, destacam-se ferramentas do modelo lean. Esse modelo de produção tem sido o núcleo de numerosas iniciativas de melhoria contínua e referenciado como necessário para o aumento da competitividade das empresas. Contudo, ao considerarmos o universo das médias empresas e a implementação de um modelo de produção, realizado como um processo contínuo de melhoria, que permite estabelecer os objetivos e as capacidades da empresa, além de orientar à melhor utilização dos recursos, é pouco utilizado, e tais organizações se apresentam ineficientes na implementação de um modelo de produção que aumente sua competitividade. Partindo dessa proposição, uma empresa que adotou como modelo de gestão da produção o lean, deveria ter, também informação acerca dos benefícios das ferramentas implementadas, bem como o seu efeito sobre o desempenho produtivo. Nesse sentido, a proposta deste trabalho consiste em avaliar quais ferramentas do modelo lean foram implementadas em cinco médias empresas do segmento automotivo, em diferentes países, se houve benefícios para o processo produtivo em função da implementação e se as ferramentas foram implementadas baseadas em algum método estruturado ou não. / The competitiveness of a company is liable to be built in different dimensions. Among them, the model of production management. And in this sense we highlight the model lean tools. This production model has been the core of numerous continuous improvement initiatives and referenced as needed to increase the competitiveness of companies. However, when considering the universe of medium enterprises and a implementation of a production model, performed as a continuous process of improvement, which allows us to establish the goals and capabilities of the company, besides guiding the best use of resources, it is rarely used and such organizations present inefficient implementation of a production model that increases their competitiveness. From this proposition, a company that has adopted as a model of lean production management, should have the information about the contribution of the tools implemented, as well as its effect on performance. In this sense, the purpose of this study is to assess which model lean tools were implemented in five medium-sized companies from the automotive sector, in different countries, there are benefits to the production process due to the implementation and tools have been implemented based on a structured method or not.

Aunque la publicación de artículos sobre la adaptabilidad y aplicación de las herramientas lean, en el sector agrícola, en las diferentes plataformas de investigación es poco explorado, en especial si se enfoca en el Perú, algunos autores y profesionales han enfatizado su adaptabilidad a este sector. En ese sentido, este artículo propone un marco para la implementación eficiente de las herramientas lean en el sector agrícola de Perú, abordando los desafíos desde una perspectiva operativa y estratégica. Para ello, el artículo se basa en investigaciones científicos publicadas por algunos expertos en la materia de la filosofía lean, estas investigaciones incluyen revisiones de literatura, modelado y casos de éxito. / Although the publication of articles on the adaptability and application of lean tools, in the agricultural sector, in the different research platforms is little explored, especially if it focuses on Peru, some authors and professionals have emphasized its adaptability to this sector . In that sense, this article proposes a framework for the efficient implementation of lean tools in the agricultural sector of Peru, addressing the challenges from an operational and strategic perspective. For this, the article is based on scientific research published by some experts in the field of lean philosophy, this research includes literature reviews, modeling and success stories. / Trabajo de investigación

La industria del plástico ha presentado un crecimiento continuo desde su creación en los años 50. En el Perú, esta industria ha mostrado un crecimiento de su producción de 4.5% en el 2018, superando a países como Chile y México. Sin embargo, este sector presenta un déficit comercial, debido a que la demanda nacional ha superado la oferta de las empresas, quienes presentan tiempos improductivos causados por tiempos de configuración y desabastecimiento de materia prima. El objetivo del proyecto fue incrementar la utilización de la capacidad de la planta en estudio, pues su nivel de utilización de la capacidad se encontraba 8.5% por debajo del nivel promedio del sector, ocasionando pérdidas equivalentes al 6.43% de las ventas totales del año 2019, asignadas a gastos logísticos, penalizaciones y anulaciones. Por esta razón, se diseñó un modelo de gestión de la producción basado en SMED Integrado (SMED Convencional + 5´S) y sistema DDMRP bajo un enfoque Kaizen, que se validó mediante una simulación en el software Arena. Como resultado del proceso de validación se logró incrementar el nivel de utilización de la capacidad de la planta en un 4.31%, alcanzando un nivel final de 84.86%, debido a la reducción de un 60% de tiempo de setup y un 90.05% de pardas por desabastecimiento. Finalmente, este nuevo modelo que vincula las herramientas mencionadas puede ser replicado en otras empresas del sector manufacturero que presenten el mismo problema. / The plastics industry has shown continuous growth since its creation in the 1950s. In Perú, this industry has shown a growth of its production of 4.5% in 2018, surpassing countries such as Chile and Mexico. However, this sector has a trade deficit due to national demand has exceeded the supply of companies, which have unproductive times caused by set-up times and shortages of raw materials. The project´s objective was to increase the capacity utilization of the plant under study because the current level of utilization of the company's capacity was below 8.5% of the average level of the sector, causing losses equivalent to 6.43% of total sales for the year 2019, assigned to logistics expenses, penalties and cancellations. For this reason, we designed a production control model based on the integrated SMED (Conventional SMED + 5´S) and DDMRP system under a Kaizen approach, which was validated through a simulation in Arena´s software. As a result of the validation process, it was possible to increase the level of plant capacity utilization by 4.31%, reaching a final level of 84.86%, due to a 60% reduction in setup time and a 90% reduction in the stops due to shortages. Finally, this new model that links the mentioned tools can be replicated in other companies in the manufacturing sector that present the same problem. / Trabajo de investigación

El presente artículo de investigación desea poner en conocimiento al lector, la baja productividad existente en la producción de alimentos orgánicos; este estudio, se enfocará específicamente en la producción de uva. El análisis e información recabada en el sector de la agricultura orgánica, ha permitido descifrar que esta problemática surge a raíz de los tiempos improductivos que se originan en cada fase de la producción de uva orgánica, generando sobrecostos innecesarios, a ello se le suma la inexistencia de procedimientos que deberán seguirse para mantener una producción sin mermas y correctamente estandarizada. El objetivo final del presente estudio fue reducir tiempos improductivos en una MYPE del sector agrícola, identificando y solucionando el problema principal y evitando la aparición de sus causas raíz. El principal problema encontrado fue el tiempo improductivo que se genera en los procesos de Abonado y Cosecha. Método: para dar solución a dicho problema, se diseñó un modelo de estandarización de procesos, empleando la herramienta de mejora continua PDCA. Resultados: como principal resultado del modelo propuesto de estandarización tenemos que la productividad se incrementó en un 25% en relación a la última producción del año 2019, además, entre otros resultados, se obtuvo la reducción en los tiempos improductivos en un 36%, lo que significó para la empresa un ahorro de S/. 5,762.62. Conclusión: El estudio demostró que, con un replanteamiento ordenado de los procesos y la disposición de la empresa a cooperar con la mejora, se pueden lograr resultados positivos, a pesar de que el proyecto no significa una gran inversión. / The present research article wishes to bring to the attention of the reader the low productivity that exists in organic food production; this study will focus specifically on grape production. The analysis and information gathered in the organic agriculture sector has allowed us to decipher that this problem arises due to the unproductive times that originate in each phase of the production of organic grapes, generating unnecessary costs. The final objective of the present study was to reduce unproductive time in an MSE of the agricultural sector, identifying and solving the main problem and avoiding the appearance of its root causes. The main problem found was the unproductive time generated in the Fertilizer and Harvest processes. Method: To solve this problem, a process standardization model was designed, using the PDCA continuous improvement tool. Results: As the main result of the proposed model of standardization we have that productivity increased by 25% in relation to the last production of 2019, in addition, among other results, we obtained the reduction in unproductive time by 36%, which meant a saving of S/. 5,762.62 for the company. Conclusion: The study showed that, with an orderly rethinking of processes and the company's willingness to cooperate with improvement, positive results can be achieved, even though the project does not involve a large investment. / Trabajo de investigación

Purpose – The purpose of this study is to increase the knowledge about the material handling of a module house manufacturing company. In order to achieve the study's purpose, three research questions were formulated. ▪ Which factors affect material handling? ▪ Which factors are considered important for material handling? ▪ How can standardization improve material handling? Method – The study has been characterized by an inductive approach to conducting the case study. To achieve the purpose, empirical data has been collected via a pilot study, interviews, observations, and document studies from reality. Subsequently, previous theories were examined via a literature collection. Furthermore, the processing and analysis of collected empirics and theory have helped to answer the purpose and demonstrate the generalizability of the study. Findings – The study has focused on the entirety of the various processes and an understanding of the various factors that influence material handling has been obtained. The case study company has challenges to look at the entirety of the modular house production and separates the production and construction sites. The wastes transport, movement, waiting and unused skills are considered to be the most important wastes to reduce or eliminate. It is clear that the case study company’s new employees must constantly reinvent the wheel and learn from their own mistakes. Moreover, it is difficult to determine if the mistake is a deviation, error or insufficient knowledge. By implementing a standard for what should be on drawings and how materials are to be delivered from production to the construction sites, deviations and wastes can be reduced and costs reduced. Implications – The study is based on a problem area that already exists in separate theories and comparisons. However, operations that have a material handling that both concerns manufacturing and construction work have not previously been investigated to the same extent, which is the theoretical contribution of the study. The empirical contribution to the study is to identify which factors affect material handling in businesses that have common flows between manufacturing and construction work. Limitations – The study only addresses two of the material handling flows; the material flow and the information flow. The study also does not take into account the processes of suppliers, subcontractors, or customers. Finally, the study will not include financial calculations to demonstrate potential cost efficiencies. Keywords – Material handling, Lean, Construction logistics, Wastes, Current flow, Value stream mapping, Lean tools.

Background: The literature on lean service and practical implementation of lean service is very thin, as the use of lean as a tool in service-oriented companies is not as well established as in the industrial and manufacturing sectors. This has created an interest in us to investigate how lean service and lean tools can be adapted to be used in the construction industry. Purpose: The purpose of this study is to identify non-value adding activities and problem areas to provide suggestions regarding leantools that can help to improve the carpentryproject process from beginning to end. Methodology: To answer the question of which non-value adding activities arise in carpentry-projects and which activities and areas in the carpentry processes that could be improved through leantools, have been studied as a case study in a medium-sized construction company. A total of four interviews were conducted, in an early stage a pilot interview with the group manager was conducted to form an idea of the current situation in the case company. Thereafter three semi-structured interviews were conducted with the company's board member, group manager and an employed carpenter. The Lean tools 5S and Muda sets the theme of the interviews and addresses issues related to waste, nonvalue adding activities and work routines. The material gathered from the interviews is set against the theoretical frame of reference and forms the basis for the analysis and discussion of this study. Results: The interviews revealed that mistakes, rework, unnecessary movements and waiting times are common. Usually in the form of incorrect drawings, poor conditions in workplaces or inadequate planning before carrying out the work in the delimited area of wall-projects. The case company recognizes that a development should take place in certain areas, but that inefficiency is not only due to them, but also to external circumstances. Contributions: Modifications to the original eight waste categories have been made to more accurately represent wastes that arise in service-oriented professions. Problems that arise in connection with non-value-creating activities are largely due to a lack of communication, unengaged employees, and inadequate planning. The results of this study validate previous research in the area of lean service and contributes with a unique perspective, as the construction industry is difficult to define as it can neither be defined as manufacturing, production oriented nor service oriented. / Bakgrund: Litteraturen kring lean service och praktisk implementation av lean service är väldigt tunn, då användningen av lean som ett verktyg inom serviceinriktade företag inte är lika väl etablerat som inom industri- och tillverkningssektorn. Detta har skapat ett intresse hos oss till att undersöka hur lean service och leanverktyg kan anpassas till att användas inom byggbranschen. Syfte: Syftet med detta arbete är att identifiera icke-värdeskapande aktiviteter och problemområden för att kunna ge förslag på leanverktyg som kan användas för att förbättra processen från att ett finsnickeriprojekt påbörjas till att det slutförs. Metod: För att svara på frågan om vilka icke-värdeskapande aktiviteter som uppstår inom finsnickeriprojekt samt vilka aktiviteter och områden i finsnickeri processen som skulle kunna förbättras med leanverktyg har undersökning skett som en fallstudie i ett medelstort snickeriföretag. I detta arbete så har totalt fyra intervjuer genomförts, i tidigt skede så genomfördes en pilotintervju med gruppchefen för att bilda en uppfattning om nuläget i fallföretaget. Därefter genomfördes tre semistrukturerade intervjuer med företagets styrelseledamot, gruppchef och en anställd snickare. Leanverktygen 5S och Muda utgjorde temat för intervjuns riktning och behandlar frågor gällande slöseri, ickevärdeskapande aktiviteter och arbetsrutiner. Underlaget från intervjuerna ställs mot den teoretiska referensramen och utgör grunden för analysen och diskussionen. Resultat: Intervjuerna visade att misstag, omarbete, onödiga rörelser och väntetider är vanligt förekommande. Vanligtvis i form av felaktiga ritningar, dåliga förutsättningar i arbetsplatsen eller brist på god planering inför arbetet inom det avgränsade området väggprojekt. Fallföretaget inser att en utveckling bör ske inom vissa områden, men att ineffektivitet inte endast beror på dem, utan även av externa förhållanden. Bidrag: Modifikationer av de ursprungliga åtta slöserikategorierna genomförts för att mer precist representera slöserier som uppstår inom serviceinriktade yrkesområden. Problemområden som uppstår i samband med icke-värdeskapande aktiviteter beror till stor del på bristande kommunikation, oengagerade medarbetare och otillräcklig planering. Resultatet från arbetet styrker tidigare forskning inom området för lean service och bidrar med ett unikt perspektiv då byggbranschen är svårdefinierad då det varken kan definieras som fullt tillverkande, produktionsorienterat eller serviceinriktat

Implementeringen av Leanverktyg i sågverksindustrin är fortfarande nyjämfört med andra industrier. Syftet med denna studie är därför att ökakunskapen om tillämpningen av Lean och se vilken effekt det har. Måletär att se vilka Lean-verktyg som är lämpliga för denna industri och hur dekan tillämpas. En kartläggning av fallföretagets nuvarande tillstånd skapasoch analyseras, och flera slöserier identifieras. Det undersöks också vilkaandra Leanverktyg som kan tillämpas effektivt. Ett TAK värde beräknasutifrån värdeflödesanalysen samt processens effektivitet. På grund avomständigheterna är våra resultat mycket missvisande och bättretillämpningar av Leanverktyg diskuteras. Som en följd av våraavgränsningar rekommenderas ytterligare forskning för att uppnå enbättre rapport. / The implementation of Lean tools in the sawmill industry is still new compared to the other industries. Therefore the purpose of this study is to increase the knowledge around the application of Lean and see the effect it has. The objective is to see which Lean tools are suited for this industry and how they can be applied. A map of the current state of the case company is created and analyzed, and several wastes are identified. It is also researched which other Lean tools can be applied effectively. An Overall equipment effectiveness value is calculated from the Value stream map as well as the process efficiency. Due to the circumstances our results are very misleading and better applications of Lean tools are discussed. As a consequence of our boundaries further research is advised to achieve a better report.

El presente trabajo de investigación tiene como principal objetivo identificar, analizar y mejorar los principales procesos del servicio integral de sepelio en la empresa Servicios Funerarios Campo Fe SAC, para afrontar la creciente demanda por el Covid-19, con el fin de identificar y reducir las actividades que no generan valor al proceso, así como de optimizar todas aquellas actividades que sí generan valor, reduciendo desperdicios y logrando un proceso más esbelto, ganando mayor competitividad y reduciendo costos. El trabajo está compuesto por cinco capítulos: en el primer capítulo se desarrolla el estado del arte, marco teórico, casos de éxito y normatividad; en el segundo capítulo se procede a describir la situación actual de la empresa mediante el diagnóstico; en el tercer capítulo se expone la propuesta de mejora de los procesos; en el cuarto capítulo se muestra el impacto económico y la validación de la propuesta de mejora y por último en el capítulo cinco, se presentan las conclusiones y recomendaciones de la aplicación del presente trabajo de investigación. Para ello se utilizaron herramientas de Lean Manufacturing mejorando los tiempos de los principales procesos (Takt Time). Todo ello mostró una mejora en la organización de los espacios de trabajo (5S). La aplicación de la filosofía Lean redujo costos y mejoró la productividad de la empresa, con lo cual se alcanzó una disminución acumulada en el tiempo de servicio integral de sepelio. / The objective of this investigation is to identify, analyze and improve the main processes of the integral burial service in Campo Fe SAC, in order to help them face in a more appropriate way the growing demand for Covid-19. The focus is to identify and reduce the activities that do not generate value to the process, as well as to optimize all those activities that do generate value, reducing waste and achieving a leaner process, gaining greater competitiveness and reducing costs. This study has five chapters: the first chapter shows a summary of the state of the art, theoretical framework, success stories and regulations; the second chapter describes the current situation of the company through the diagnosis; the third chapter presents a proposal to improve the processes; the fourth chapter shows the economic impact and validation of the improvement proposal and the fifth chapter presents the conclusions and recommendations of the application of this research. The current work applies Lean Manufacturing tools to improve the time of the main processes (Takt time). Results showed an improvement in the organization of workspaces (5S). The application of Lean philosophy reduced costs and improved the productivity of the company, achieving a cumulative decrease in the comprehensive burial service time. / Trabajo de investigación