"Starting in the 1980s with the first Toyota controlled production plant in the United States (NUMMI), the idea of Lean as derived from the Toyota Production System has become a popular method to improve production processes as well as any other procedure in organizations around the world. Over the last three decades a multitude of literature on Lean implementation and consulting companies offering help with the Lean transformation have emerged. The success rate of real Lean transformations however is often estimated to lie below 10% by experts such as Clifford Ransom or members of the Society of Manufacturing Engineers (SME). This leads to the question of why most companies fail to sustain the Lean improvements that most of them are able to initiate during the early implementation stages. This thesis will therefore investigate the root causes that lead to a time dependent loss of Lean improvements from three different perspectives. One standpoint is given by the TPS beliefs which are united in the House of Lean. The second angle on the topic is drawn from an online search of expert opinions and the final evaluation is taken from analyzing a real case scenario at a plant in Trumbull, CT. After this thorough analysis of possible root causes a set of countermeasures is presented that will support an organization in avoiding the major mistakes of a Lean implementation. The three countermeasures include standardization to build a base for Lean improvements, employee involvement to assure sustainability through conviction and continuous instead of rapid improvement. Every countermeasure will be described theoretically as well as with the help of examples from real life scenarios to enable the reader to apply the suggestions immediately. A final discussion will then examine the improvements that where reached at the production plant in Trumbull, CT and show how the combination of all three countermeasures ensures the sustainability of these improvements."

Made available in DSpace on 2015-03-05T17:04:34Z (GMT). No. of bitstreams: 0 Previous issue date: 22 / Nenhuma / Considerando a premente importância dos custos, o alto volume de produção e a geração de altos níveis de estoques inerentes ao processo produtivo de resinas petroquímicas, o presente estudo analisa as práticas de armazenagem no setor sob a ótica dos princípios da Mentalidade Enxuta. Este trabalho tem por objetivo apresentar o grau de aderência das operações de armazenagem de resinas termoplásticas aos princípios da Mentalidade Enxuta, a saber: (i) especificação do valor; (ii) identificação da cadeia de valor; (iii) fluxo; (iv) estabelecimento da produção puxada; e (v) perfeição. Para tanto foi desenvolvido um instrumento de avaliação, desmembrado em cada um dos cinco princípios, apoiado por um grupo focado com especialistas nas operações estudadas. Na seqüência, o instrumento foi aplicado a profissionais da área em três armazéns do Pólo Petroquímico de Triunfo/RS, de onde se extraiu o grau de aderência das práticas de armazenagem aos princípios da Mentalidade Enxuta e as lacunas existentes. A seguir as lacuna / The present study analyses storage practices in the petrochemical sector from the point of view of Lean Thinking, taking into consideration the pressing importance of costs, the high volume of production and high volume of inventory intrinsic to the process. The main objective of the study is to present the level adherence that the operations of thermoplastic resin storage have to the principles of the Lean Thinking. The evaluation process developed was broken down into five different sections, one for each of the Lean Thinking principles. Each section had the support by a specialist in the specific field. Following that, the process was applied to professionals of the different areas in three warehouses of the Petrochemical Region of Triunfo/RS, from where it was possible to derive the level of adherence so mentioned, and the existing gaps. Finally, the gaps were jointly analyzed, and operational alternatives to fulfill them in order to better improve the adherence of the entire process to the principles

Alors que la production de masse représentait le paradigme industriel dominant dans les années 80, le Toyota Production System, le système d'amélioration continue exemplifié chez Toyota, a suscité l'intérêt de nombreux chercheurs et industriels à la recherche de moyens d'améliorer la performance opérationnelle et financière des organisations. L'objectif de la thèse repose sur la caractérisation de la dimension humaine dans les systèmes de production intégrant une forte composante d'amélioration continue dans le but de la considérer lors du processus d'adoption. Pour cela, la thèse s’oriente autour de trois contributions majeures : la définition de la dimension humaine inhérente au Lean, l'évolution historique des éléments constituants cette dimension humaine et son opérationnalisation au travers du rôle des experts du Lean dans le processus d'adoption. / While mass production was the dominant industrial paradigm of the 1980s, the Toyota Production System, Toyota's exemplary continuous improvement system, has attracted the interest of many researchers and industry in seeking ways to improve operational and financial pe1formance of their organizations. The aim of this thesis is to characterize the human dimension in production systems including a strong component of continuous improvement in order to consider it during the adoption process. For this, the thesis focuses on three major contributions: the definition of the human dimension inherent to Lean, the historical evolution of the elements that represent this human dimension and its operationalization through the rote of Lean experts in the adoption process.

Submitted by Mariana Dornelles Vargas (marianadv) on 2015-05-12T20:17:52Z No. of bitstreams: 1 proposta_ferramenta.pdf: 2337946 bytes, checksum: 0c30e57b5937580a6c29049ce4d68e8f (MD5) / Made available in DSpace on 2015-05-12T20:17:52Z (GMT). No. of bitstreams: 1 proposta_ferramenta.pdf: 2337946 bytes, checksum: 0c30e57b5937580a6c29049ce4d68e8f (MD5) Previous issue date: 2011 / Nenhuma / O pensamento enxuto tem provocado mudanças representativas nas áreas produtivas. Estas alterações vêm sendo medidas equivocadamente pelos sistemas de gestão financeira, em razão de os pressupostos ainda estarem embasados na mentalidade de produção em massa, defendendo que as otimizações locais isoladas traduzem a otimização global da empresa. Diante disso, é possível afirmar que a contabilidade tradicional não é capaz de prover as informações necessárias à correta tomada de decisão em companhias enxutas. Maskell e Baggaley (2004) enfatizam as necessidades de alinharem-se as metas do lean com as práticas financeiras. Com isso, o interesse no método da contabilidade enxuta torna-se um subproduto de interesse em todo o movimento enxuto de uma companhia. O pensamento enxuto tem por finalidade melhorar os negócios, concentrando-se naquilo que o cliente deseja, seja o cliente interno e/ou externo, eliminando etapas e processos que não agreguem valor. A Contabilidade Enxuta faz parte deste movimento, assim como todas as demais formas utilizadas para alcançar a melhoria contínua do negócio. Para o cumprimento do objetivo proposto, utilizou-se a metodologia de estudo de caso, com a aplicação em uma empresa do setor de equipamentos rodoviários fora de estrada. Como resultado, desenvolveu-se uma ferramenta capaz de medir e analisar o grau de aderência dos processos contábeis frente aos conceitos do modelo Lean Accounting. / Lean thinking has caused changes in the representative production areas. These changes have been mistakenly measures for financial management systems, because of the assumptions are still grounded in the mentality of mass production, arguing that the isolated local optima reflect the companys global optimization. Therefore, we can say that traditional accounting is not able to provide the information necessary for correct decision making in lean companies. Maskell and Baggaley (2004) emphasize the need to align themselves with the goals of lean financial practices. As a result, interest in lean accounting method becomes a byproduct of interest in the whole movement a lean company. Lean thinking aims to improve business, focusing on what the customer wants, is the internal customer and / or external processes and eliminating steps that add no value. Lean Accounting is part of this movement, as well as all other tools used to achieve continuous improvement of the business. To achieve the objective proposed, we used the methodology of case study, with the application in a company in the road off-road equipament. As a result, we developed a tool to measure and analyze the degree of compliance of accounting processes forward the concepts of Lean Accounting model.

A digitalização e a evolução tecnológica experimentadas em anos recentes têm promovido mudanças na forma como as organizações se estabelecem e desenvolvem seus modelos de negócios. São exigidos intervalos de respostas cada vez mais curtos, bem como flexibilidade e dinamismo. Algumas práticas têm emergido para auxiliar empreendedores atuantes neste novo cenário, em especial aos líderes de startups e projetos de base inovadora. O presente trabalho apresenta resultados de uma pesquisa que teve como objetivo de investigar de que forma o lean startup pode auxiliar novos empreendimentos baseados em inovação a validar seus modelos de negócio, quais os fatores críticos de sucesso para a sua implementação e qual o grau de adoção de suas práticas por startups tecnológicas na região metropolitana de Porto Alegre (RS). Para isto, o estudo foi dividido em três principais etapas. A primeira etapa consistiu em uma revisão sistemática da literatura a respeito da temática, com a identificação de estudos acerca do lean startup, customer development e gestão ágil. Foram identificados principais efeitos da implementação sobre as organizações e fatores críticos de sucesso para a execução A segunda e terceira etapas compreenderam estudos de caso múltiplos, com a identificação de práticas utilizadas por startups tecnológicas para a validação de elementos de modelos de negócio, e a coleta de percepções de líderes de startups de engenharia quanto ao lean startup e os principais obstáculos e facilitadores para a sua implementação. Entre os principais resultados, destacam-se os benefícios das práticas ágeis sobre a flexibilidade das organizações, bem como a redução de custos, se comparados à gestão baseada em planos de negócios. Deve-se ressaltar que os estudos de caso possuem limitações quanto à generalização, visto que podem não representar outras realidade. De toda a forma, o presente trabalho contribui para o preenchimento de parte de uma lacuna existente na literatura quanto à temática. / Digitization and technological evolution experienced in recent years has led to changes in the way organizations establish and develop their business models. Market demands quick responses as well as flexibility and dynamism. Some practices have emerged to assist entrepreneurs in this new scenario, especially leaders behind startups and innovation-based projects. This work presents results of a research that aimed at investigating how lean startup can support the validation of business models in innovation-based ventures, what are the critical success factors for its implementation, and whether the startups in the metropolitan region of Porto Alegre (RS) are actually adopting the methodology. To achieve this objective, the study was divided into three main stages. The first stage consisted of a systematic literature review on the subject, with the identification of studies about lean startup, customer development and agile management. As main findings, we identified lean startup effects on organizations and critical success factors for its implementation. The second and third steps included multiple case studies, identifying the practices used by technological startups to validate business models elements, and the perceptions of leaders behind engineering startups regarding to lean startup, as well as main obstacles and facilitators for its implementation. Some results regard the benefits of agile practices on the flexibility of organizations, as well as the reduction of costs, when compared to plan-based management approaches. Case studies have limitations on generalization, since they may not represent other realities. In any case, the present work contributes to fill part of a literature gap on the subject.

Lean production härstammar från företaget Toyota och Taiichi Ohno’s begrepp ToyotaProduction System. Metoden är idag ett dominerande styrmedel bland organisationer. Därmedhar konceptet implementerats i allt fler västerländska resultatstyrda organisationer, varsparametrar för kontroll skiljer sig mot de lean production utgår från. Dess innebörd sträckersig över stora delar av en organisation, vilket bidrar till begreppets komplexitet. Leanproduction förväntas ge upphov till continuous improvement samt elimination of waste.Utifrån detta har forskare formulerat 14 principer vilka sammanfattas i The Toyota Waymodel. För att erbjuda fler perspektiv till insamlad empiri har the Toyota Way model använtssom ett ramverk tillsammans med tre olika kategorier för kontroll: effekt- beteende- samtsocial styrning. Denna studie syftar dels till att identifiera formen av continuous improvementi företaget Ardaghs organisation, samt relationen mellan traditionella styrmedel och leanproduction.Studien tillämpar ett pragmatiskt förhållningssätt, med målet att insamlad empiri ska förklaraden teoretiska referensramen. Empirin samlades in genom observationer, samtal ochdokumentation från tre olika delar av Ardaghs verksamhet: administrationen, styrningen ochproduktionen. Den empirika datan samlades in med continuous improvement och internakontrollprocesser i åtanke.Studiens resultat indikerade att det i Ardaghs verksamhet förekom olika former av continuousimprovement och konflikter mellan kontrollprocesser. Formerna sammanfattas i studiensresultat genom två olika aspekter: den filosofiska och den instrumentella. Den filosofiskaaspektens utgångspunkt återfinns främst i lean productions grundförutsättningar, såsomlångsiktiga visioner, empowerment och strategier för att uppnå effektiviseringsvinster. Deninstrumentella aspekten kretsar främst kring hur lean-verktyg påverkar en organisationssjälvbild, samt hur traditionell budgetstyrning tenderar att hamna i konflikt med leanproductions metoder för kontroll. / Program: Civilekonomprogrammet

En omfattande datorisering inom företagsvärlden har skapat ett beroende av informationssystem (IS) som kan hantera och lagra information efter verksamhetens behov. Genom att investera i nya och mer effektiva IS kan verksamheter skaffa sig verktyg där de effektivt kan prioritera och allokera de resurser som finns tillgängliga. Detta gör det möjligt att omdefiniera arbetsprocesser och sysselsättningsrutiner och därmed spara arbetskraft genom att automatisera och eliminera en del uppgifter. Dock finns det en del faktorer som påverkar implementeringen av IS, exempelvis brist på resurser, teknik och kompetens. Dessa faktorer gör det många gånger mer problematiskt att utveckla IS i utvecklingsländer.Syftet med studien är att undersöka hur en organisation med begränsade resurser, kan effektiviseras genom att använda sig utav Lean IT. Studien utgår ifrån ett förändringsprojekt som genomfördes av Swedish Development Advisers (SDA), på uppdrag från Sida, för att förenkla IT-stödet för de krigsskadades myndighet i El Salvador. Myndigheten är en kombination av Arbetsförmedlingen, Försäkringskassan och remitterande sjukvård med 36 000 handikappade som kunder. SDA lyckades förkorta myndighetens handläggningstider med 90 % genom en förenkling av organisationens informations- och kommunikationsteknologier. Vi ser idag ett liknande problem inom Sverige där Försäkringskassan kritiseras på grund av de allt för långa handläggningstiderna, varpå vi även drar generella jämförelser med denna myndighet.Studien har genomförts med en hermeneutisk ansats av kvalitativ art. Där empirin insamlats genom intervjuer med SDA, samt svensk rikspress där problematiken kring Försäkringskassan har debatterats. Därefter analyserade vi hur väl SDA använde sig utav Lean IT vid genomförandet av projektet i El Salvador. Vidare gjordes en jämförelse mellan de olika myndigheterna för att kunna ta fram likheter i den problematik som har kunnat urskiljas inom organisationerna. Detta gjordes för att kunna undersöka om även Försäkringskassan bör använda sig utav Lean IT för att effektivisera verksamheten.Med studien har vi kommit fram till följande slutsats. Omstruktureringsprojektet i El Salvador är ett mycket gott exempel på hur en organisation kan effektiviseras genom Lean IT. Projektet gav ett mycket gott resultat med förenklade och förbättrade processer som följer det behov som finns bland de krigsskadade. Vi kom även fram till att den problematik som finns inom Försäkringskassan liknar i stor utsträckning de problem som fanns inom myndigheten för de krigsskadade innan effektiviseringsprojektet. SDA lyckades genom Lean IT att upptäcka och eliminera de problem som fanns. Vi anser att detta tyder på att det går att eliminera de liknande problem som finns inom Försäkringskassan med samma metod. / Program: Dataekonomutbildningen

With the fast a growth of the global economy and the competition in the world, all business enterprises are trying to deliver their products at the lowest possible price and at high quality. At the same time businesses should run in profit. This is possible by reducing waste and introducing new technology like information technology (IT). IT provides necessary information for the customers regarding the new products, quality and recent features about the product design. By using databases in the enterprise, recent market trends and customer needs can be known in advance and the product design can be changed and make the customers more satisfaction. IT also plays an important role in the security of information in the enterprise and also security to the customers regarding product delivery and product details. Lean management systems provide the new ideas about the non value and unnecessary activities in the enterprise. Ultimately Lean reduces the wastage and improves the customer satisfaction. Our thesis focuses on advantages of lean-IT in business enterprise and how information technology can be useful in customer service and continuous improvement by utilizing knowledge management.

Inom IT-branschen läggs det mycket resurser på att effektivisera arbetssätt, och att hitta det optimala sättet att styra och leda projekt är en ständig utmaning. Dagens IT-organisationer befinner sig även i en situation där marknaden ställer krav på minskade kostnader men samtidigt en högre nivå av support och service. Utifrån detta har det genererats en uppsjö olika arbetssätt och tillhörande verktyg som alla har som mål att strukturera eller effektivisera systemutvecklingsprocessen. Ett av dessa arbetssätt är Lean IT som hämtar sina grunder från det väl beprövade produktionssystemet Lean Manufacturing.Inom systemutvecklingsbranschen arbetas det ofta i projektform och att ha en bra projektledning är ofta en av faktorerna bakom ett lyckat projekt. För att en projektledare ska kunna leda projektet till framgång krävs det att denne har en bra uppfattning om arbetssättet inom organisationen och projektgruppen. Denna rapport fokuserar därför på om en projektledares arbetsuppgifter inom Lean IT förändras gentemot ett mer traditionellt arbetssätt, och i så fall hur projektledarens arbetsuppgifter ser ut inom Lean IT. Informationen i studien har samlats ihop genom intervjuer med ett flertal kontaktpersoner på tre olika företag som alla inkorporerar Lean IT i sina arbetssätt, samt via deltagande observation på ett mikroföretag inom systemutvecklingsbranschen i Borås.Genom att jämföra insamlad data om en projektledares arbetsuppgifter i Lean IT-projekt med den traditionella projektledarens arbetsuppgifter som dessa är beskrivna i litteratur, har ett antal skillnader påvisats. Lean IT förespråkar ett mycket närmare samarbete mellan projektgruppen och projektledaren och en mer intensiv involvering i projekt från projektledarens sida, och detta visar sig i rapporten överensstämma med hur de studerade företagen har använt Lean IT i praktiken. Dessutom konstateras det att projektledning inom Lean IT på många nivåer är starkt relaterad till traditionell projektledning. Istället för att ha resulterat i helt nya arbetsuppgifter grundar sig snarare projektledning inom Lean IT i den traditionella projektledningen och därifrån vidareutvecklat sättet att arbeta på. / Program: Systemarkitekturutbildningen

This thesis reflects upon several decades of research into Lean Production systems, highlighting the need for further investigation using an empirical study of exemplar implementations of Lean. The initial point of departure is an analysis of the current views of Lean based on a detailed literature review. The resulting Views of Lean Table provides a framework for the investigation of an exemplar Lean operation, viz the Nissan Sunderland Plant, widely regarded to be one of the most productive automotive plants in Europe. The exploratory nature of this investigation, and unique opportunity for access, argued for the use of an inductive single case study as an appropriate research approach. A four phase approach was used to; a) identify views of Lean, b) gain an initial understanding of the Nissan Production Way at the Nissan Sunderland Plant, b) acquire a detailed description of the Nissan Production Way and c) to assess the level of intrinsic motivation amongst employees. The primary objective of this research is to establish whether our current knowledge of Lean sufficiently encapsulates the concept’s many facets. Detailed semi-structured interviews with Nissan Production Way experts revealed that Nissan Sunderland Plant’s production system uses a large number of elements in contrast to the relatively narrow list of ‘Lean’ elements cited in the Views of Lean Table. In contrast to academic theory there was a focus on extrinsic motivation with low intrinsic motivation offset by the plant’s continuous fight for survival and ‘whatever-it-takes’ attitude. In practice Lean is viewed as an overarching philosophy with a toolkit encompassing a wide range of tools which are used when they are suitable for the task in hand.