Twenty first century manufacturing is characterized by customer specific products. Customers expect greater differentiation in the products that companies offer to them, thus changing the whole landscape of production. Greater the variety of products being offered to customers, greater is the complexity of shop floor operations. This complexity is translated to all the operations in the shop floor including material handling and inventory control. To overcome this situation, many manufacturers have turned to “Lean Manufacturing” to gain a competitive edge in the market by reducing costs and improving productivity in all operations throughout the shop floor. Therefore, this purpose of this thesis is to analyze the material handling of a highly customized multi-variant product-based production system. The thesis represents a case study that was done at a caravan manufacturing company in Tenhult, Sweden. During the study, data was gathered from field notes, observations and multiple semi-structured interviews. The findings were analyzed with respect to a theoretical background which was generated through an extensive literature review that was carried out throughout the research. Our analysis was based on a systems approach where the findings were categorized into three dimensions that affect material handling and inventory control. These dimensions are warehouse management systems, culture, and production management, which contribute to successful implementation of lean into the material handling operations and inventory control. In conclusion, the results show that efficient material handling and inventory control can only be achieved by finding a synergy between technology, people and organization. Our results also show that soft issues like organizational culture and employee culture need to be addressed along with technological issues because only when an alignment between people, technology and business objectives and values is achieved, lean implementation can be successful. Our results also show the need for better supplier customer collaboration to reduce inventory levels and material handling operation.

There is a gap in the research regarding applications of Lean tools in the wood fiber supply chain. A Value Stream Map (VSM) tool that focused on identifying Lean waste in logistic operations was developed and applied to three case study firms: a paper mill, a sawmill, and a logger. Using the VSM tool an absence of structured methods to select and assess suppliers was found, which promotes a fluctuating environment for suppliers. Therefore, a tool that implements a hierarchy system to categorize suppliers was developed, verified and validated. Through the use of the VSM implementation the author found a lack of information sharing between supply chain stakeholders, which causes a reactive environment for the industry. Improvements in wood flow planning, tract allocation, truck scheduling, and communication were projected as a future state of the system. The annual potential savings by implementing the projected improvements in the total cost were as follows for the paper mill, the sawmill, and the logger respectively: $306,232, $312,085, $756,504. As a result of the findings obtained through the VSMs, a supplier selection model was designed. The tool was implemented into software for the wood industry. The tool was then verified and validated. The verification process consisted of comparing the output through previously known results and was performed through seven interviews with different stakeholders. The appropriate application of the supplier selection tool improves the way in which companies in the wood industry select and assess their suppliers and guarantee that the best alternatives are selected. / Master of Science / In the wood fiber supply chain, integration between different parties within a supply chain has proven to be a difficult task. An innovative lean-logistics tool value-streamed map (VSM) was developed to evaluate the current and future state of a supply chain Once the tool was developed it was used to map the wood fiber supply chain, determine and measure key performance metrics, calculate the cost of logistics operations, and identify potential sources of waste. Three case studies representing common wood fiber supply chains were conducted to develop three current VSMs for selected value streams. The lack of communication between supply chain partners was determined to be the most significant source of waste in all three cases. Lack of communication could lead to idle equipment, unnecessary waiting times, excessive inventories, overproduction, and excessive transportation and movement. As a result of the findings obtained through the VSMs, which revealed the absence of structured methods to select and assess suppliers, a supplier selection model was designed. The tool was implemented into software for the wood industry. The tool was then verified and validated. The verification process consisted of comparing the output through previously known results and was performed through seven interviews with different stakeholders. The appropriate application of the supplier selection tool improves the way in which companies in the wood industry select and assess their suppliers and guarantee that the best alternatives are selected, thus increasing the chance of a successful relationship and increasing the value that the company gets from its supplier base.

The aim of this thesis is to analyze the material flow in a company located at the second stage of the supply. Material flow is monitored in terms of logistics. The focus becomes reducing production lead times due to optimized inventory. In the theoretical section briefly summarizes the nature of material flow and the means used to optimize inventory. The content of the practical part is a detailed conflict of manufacturing and non-manufacturing operations, which will be the basis for possible suggestions to improve all material flow.

Submitted by Fabio Medeiros (medeirosfb@hotmail.com) on 2018-08-29T19:18:50Z No. of bitstreams: 1 DissertaçãoOficial_FabioMedeiros_Final_2018-07-13.pdf: 1886756 bytes, checksum: 97237a802cf505a292bc9315360ed503 (MD5) / Approved for entry into archive by Mayara Costa de Sousa (mayara.sousa@fgv.br) on 2018-09-05T18:08:23Z (GMT) No. of bitstreams: 1 DissertaçãoOficial_FabioMedeiros_Final_2018-07-13.pdf: 1886756 bytes, checksum: 97237a802cf505a292bc9315360ed503 (MD5) / Approved for entry into archive by Suzane Guimarães (suzane.guimaraes@fgv.br) on 2018-09-06T12:15:47Z (GMT) No. of bitstreams: 1 DissertaçãoOficial_FabioMedeiros_Final_2018-07-13.pdf: 1886756 bytes, checksum: 97237a802cf505a292bc9315360ed503 (MD5) / Made available in DSpace on 2018-09-06T12:15:47Z (GMT). No. of bitstreams: 1 DissertaçãoOficial_FabioMedeiros_Final_2018-07-13.pdf: 1886756 bytes, checksum: 97237a802cf505a292bc9315360ed503 (MD5) Previous issue date: 2018-07-04 / As grandes corporações têm intensificado a otimização de suas redes logísticas, entendendo a importância estratégica que a área de operações possui, não somente em relação a liberação de recursos através de redução de custos, mas também na geração de valor através dos serviços prestados a seus clientes. Este movimento trouxe consigo um amplo desenvolvimento tecnológico para as operações de distribuição e logística. No que diz respeito a automação, existe uma evolução significativa, principalmente nos processos internos dos centros de distribuição, tais como: sistemas inteligentes de guarda e retirada de produtos, operações de empilhadeiras sem tripulação humana, carregamento e descarregamento mecanizado de caminhões, sistemas automatizados de separação de pedidos e máquinas para montagem e fechamento de caixas, entre outros exemplos. No entanto, não há uma grande variedade de estudos de casos sobre operações, já automatizadas, que elevaram seus níveis de produtividade e qualidade significativamente, sem investimentos de capital, mas através de redesenho de processos e atuação das lideranças operacionais. Este trabalho, portanto, tem como objetivo capturar e demonstrar o que foi realizado para se obter ganhos significativos em produtividade e qualidade nas operações logísticas através desta união: ferramentas de melhoria contínua e atuação das lideranças, sem o uso de investimentos de capital. O problema de pesquisa está focado, então, em capturar e demonstrar as iniciativas implementadas durante a transformação pela qual o processo de distribuição da empresa passou em relação as suas atividades logísticas, bem como as ferramentas de melhoria contínua utilizadas. Para tanto, foi realizada uma pesquisa do tipo estudo de caso da operação logística da Avon Cosméticos no Brasil, entre os anos de 2015 a 2017, que passou por este processo de transformação. Como resultado, espera-se detalhar estes projetos e iniciativas implementados bem como as metodologias ou ferramentas aplicadas, as melhorias obtidas e a conexão entre teoria e prática. Como aporte deste trabalho, espera-se reforçar a teoria existente sobre melhoria contínua de processos, contribuindo assim com os mundos acadêmico e empresarial no que diz respeito a otimização de operações. / Large corporations have intensified the optimization of their logistics networks, understanding the strategic importance that the operations area has not only related to the resources release through cost reduction, but also in value generation through the services provided to its customers. This movement brought with it a broad technological development for distribution and logistics operations. As far as automation is concerned, there is a significant evolution, especially in the internal processes of distribution centers, such as: intelligent systems for guarding and withdrawing products, forklift operations without human crew, mechanized loading and unloading of trucks, automated separation of orders and machines for assembly and boxes closing, among other examples. However, there is not a wide range of case studies on operations, which are already automated, that have raised their levels of productivity and quality significantly, without capital investments, but through processes redesign and the performance of operational leadership. This work, therefore, aims to capture and demonstrate what has been done to achieve significant gains in productivity and quality in logistics operations through this union: tools for continuous improvement and leadership performance, without significant use of capital capex. The research problem is then focused on capturing and demonstrating implemented initiatives during the transformation by which this company's distribution process passed related to its logistic activities, as well as the continuous improvement tools used. To do so, a case-study of the logistics operations of Avon Cosmetics in Brazil, between the years of 2015 and 2017, was carried out. As a result, it is expected to detail these projects and initiatives implemented as well as the methodologies or tools applied, the improvements obtained and the connection between theory and practice. As a contribution of this work, it is hoped to reinforce the existing theory on continuous process improvement, thus contributing to the academic and business worlds regarding to operations optimization.

Graduation theses is dealing New logistic concept, which is in these days implemented in concern Volkswagen. Author, employee of Škoda company, describes New logistic concept at all in its five moduls and he is evaluating its principles with the modernest logistic theory. In practical part he analyses factuality of concrete Milkrun establishing in order of New logistic concept principles. Work results with confirmation of funcionality of new principles through concrete exam of Milkrun. It containes also common recomendation for successful realisation the whole concept.

En el siguiente proyecto, se estudiarán las utilidades fundamentales de la aplicación de la metodología Lean Logistics en el área de compras para la empresa Tecnomina S.A.C. El trabajo estará orientado en la obtención de resultados, en el incremento de la rotación de inventarios, eliminación de desperdicios y la obtención del stock necesario con la implementación de la metodología logística esbelta y sus herramientas justo a tiempo y 5S en el momento oportuno para atender a nuestros clientes evitando la anulación de las órdenes de compra generadas por las roturas de stock, para ello se presentarán cinco capítulos en este proyecto. En el primer capítulo, se entenderá el entorno relacionado a los conceptos generales del proyecto de investigación; en el segundo capítulo se realizará el análisis de la situación actual de la empresa para la interpretación del problema; en el tercer capítulo se propone la selección y aplicación de la metodología utilizando las herramientas correspondientes para la solución del problema; en el cuarto capítulo, se validará la propuesta de mejora del proyecto simulando el proceso en diferentes situaciones referidas a los productos analizados y se aprobará con el flujo de caja económico y el plan de actividades y cronograma. En el último capítulo se realizarán las conclusiones y recomendaciones de todo el proyecto de investigación. / In the following project, the fundamental utilities of the application of the Lean Logistics methodology in the purchasing area for the company Tecnomina S.A.C will be studied. The work will be oriented towards obtaining results, in increasing the inventory rotation, elimination of waste and obtaining the necessary stock with the implementation of the lean logistics methodology and its tools just in time and 5S at the right time to serve our customers, avoiding the cancellation of purchase orders generated by stock breaks, for this five chapters will be presented in this project. In the first chapter, the environment related to the general concepts of the research project will be understood; in the second chapter the analysis of the current situation of the company will be carried out to interpret the problem; in the third chapter the selection and application of the methodology is proposed using the corresponding tools for solving the problem; in the fourth chapter, the project improvement proposal will be validated by simulating the process in different situations related to the analyzed products and it will be approved with the economic cash flow and the activities plan and schedule. In the last chapter, the conclusions and recommendations of the entire research project will be made. / Trabajo de Suficiencia Profesional