A metodologia lean é uma alternativa para melhorar a competitividade da empresa, porém, o baixo percentual de sucesso destes projetos ressalta a necessidade da gestão dos riscos envolvidos em tais projetos. Esta dissertação apresenta quatro contribuições principais para o tema: (i) identificação dos fatores de risco ao sucesso de projetos de implantação da metodologia; (ii) identificação da intensidade do relacionamento entre os fatores de risco; (iii) algoritmo para estimativa da probabilidade de sucesso de projetos de implantação da metodologia; (iv) sistema de suporte à decisão para projetos de implantação da metodologia considerando os fatores de risco e a importância estratégica do projeto para a empresa. Através de revisão da literatura e análise de especialistas da academia e da indústria, foram identificados os fatores de risco ao sucesso dos projetos de implantação da metodologia lean e foi levantada a intensidade do relacionamento entre os mesmos. O algoritmo proposto, considerando os fatores de risco modelados como um sistema série-paralelo, utiliza preceitos da confiabilidade para estimar a probabilidade de sucesso do projeto de implantação. O sistema de suporte à decisão proposto avalia a probabilidade de sucesso do projeto estimada frente à probabilidade alvo de sucesso, definida de forma qualitativa conforme à importância do projeto para a empresa. Se necessário, metas otimizadas para a situação dos fatores de risco são calculadas via algoritmo de otimização. A aplicação do modelo em empresas de grande porte apresentou resultados coerentes, possibilitando avaliar a viabilidade do projeto de implantação e definir metas otimizadas para a situação dos fatores de risco, fornecendo assim, informações importantes para a gestão do projeto. / The lean methodology is a strategy to improve company‘s performance, however, the low percentage of success of these projects highlights the need for risk management in such projects. This dissertation presents four main contributions to this subject: (i) identification of the risk factors in projects of lean methodology implementation, (ii) identification of the intensity of the relationship between the risk factors, (iii) an algorithm for estimating the probability of successful implementation for lean projects, (iv) a decision support system for methodology implementation considering the risk factors and the strategic importance of the project for the company. Through literature review and analysis of experts from academia and industry the risk factors to the successful implementation of the lean methodology were identified and the intensity of the relationship between them was raised. The proposed algorithm, considering the risk factors modeled as a series-parallel system, use reliability principles to estimate the likelihood of successful project implementation. The decision support system proposed assesses the estimated probability of success of the project against the target probability of success, defined qualitatively according to the importance of the project for the company. If necessary, goals for the risk factors status are calculated via optimization algorithm. The application of the model in large companies showed consistent results, allowing assessing the feasibility of the project and setting goals for the optimal status of the risk factors, providing managers with important information for project management.

O setor automotivo se caracteriza pela busca por redução de custos e de desperdícios em seus processos produtivos. Desta forma, torna-se necessário o uso de melhores práticas para se manter competitivo no mercado. Dentre estas práticas, destaca-se a metodologia Lean Manufacturing (LM), proveniente do Sistema Toyota de Produção, a qual propõe melhorias nos processos, por meio da eliminação das perdas. Mesmo que estudos estejam em andamento e que, eventualmente, suas ferramentas sejam empregadas de forma isolada no meio empresarial, não há um consenso a respeito do tema e das principais métricas utilizadas para verificar seus benefícios quando da implantação e uso integral das práticas enxutas. Sob este aspecto, a dissertação buscou compreender, por meio de um estudo de caso múltiplo exploratório com abordagem qualitativa, como os fatores contextuais influenciaram o uso de práticas Lean e suas métricas de avaliação em cinco empresas do setor automotivo da Serra Gaúcha. Com base na bibliografia sobre o tema e nos instrumentos de pesquisa aplicados, obteve-se, como resultado central, a compreensão sobre quais são os fatores contextuais que influenciaram ou ainda influenciam o uso de práticas enxutas, além do levantamento de quais eram as principais métricas utilizadas nestas empresas para fortalecer e aprimorar seu sistema produtivo. / The automotive sector is characterized by the search for cost reduction and waste in their production processes. Thus, it becomes necessary to use best practices to stay competitive in the market. Among these practices, there is the Lean Manufacturing (LM), from the Toyota Production System, which proposes process improvements through the elimination of waste. Even if studies are in progress and that eventually, their tools are employed in isolation in business world, there is no consensus on the subject and the main metrics used to verify its benefits when deploying and full use of lean practices. In this regard, this dissertation aimed at understanding, through an exploratory multiple case study with a qualitative approach, how the contextual factors influencing the use of Lean practices and its evaluation metrics in five companies belonging to the automotive sector in south region of Brazil. Based on the literature about the subject and applied research tools, was obtained as a central result, the understandings of which were the contextual factors that influenced or influence the use of Lean practices, besides a survey of the key metrics used in these companies to strengthen and enhance its production system.

Esse trabalho apresenta uma empresa nacional do ramo metalúrgico fabricante de autopeças tubulares, que implantou conceitos da manufatura enxuta na linha de seu principal produto. A metodologia utilizada foi o mapeamento do fluxo de valor e o levantamento de índices, que refletissem a situação atual no início do trabalho, passando pela análise dos processos produtivos e viabilidade da implantação dos conceitos da manufatura enxuta. Os resultados apresentam uma análise crítica das técnicas implantadas e das melhorias alcançadas, além dos ganhos em produtividade e diminuição das perdas por retrabalhos e refugos dos produtos, melhoria na eficiência dos operadores e melhoria no layout da célula. Foi observada a importância na indústria do conceito de manufatura enxuta, assim como seus resultados positivos frente à expectativa e objetivos gerados no início da implantação. / This study shows a national company in the industry Metallurgical, facing the automotive industry that manufactures auto parts and tubes that deployed the concept of lean manufacturing in line of your main product. The methodology began with the mapping of the flow and raising of indices that reflect the current situation, through analysis of processes and feasibility for implantation of the concepts of lean manufacturing. The results presents a critical analysis of developments and improvements achieved, plus the gains in productivity and reduction of rework and scrap products. Are also made suggestions for future studies and projects. In this work we observed the importance of the concept of lean manufacturing in the industry, as well as its positive results compared to expectations generated at the beginning of implantation in order to help further the dissemination of the concept in the industry.

Submitted by Divisão de Documentação/BC Biblioteca Central (ddbc@ufam.edu.br) on 2018-04-19T19:08:45Z No. of bitstreams: 2 DISSERTAÇÃO ELLEN SEGADILHA_REVISÃO FINAL_.pdf: 1594859 bytes, checksum: 54ef3c18b30fab0a3f3373b62c9089bc (MD5) license_rdf: 0 bytes, checksum: d41d8cd98f00b204e9800998ecf8427e (MD5) / Approved for entry into archive by Divisão de Documentação/BC Biblioteca Central (ddbc@ufam.edu.br) on 2018-04-19T19:09:00Z (GMT) No. of bitstreams: 2 DISSERTAÇÃO ELLEN SEGADILHA_REVISÃO FINAL_.pdf: 1594859 bytes, checksum: 54ef3c18b30fab0a3f3373b62c9089bc (MD5) license_rdf: 0 bytes, checksum: d41d8cd98f00b204e9800998ecf8427e (MD5) / Made available in DSpace on 2018-04-19T19:09:00Z (GMT). No. of bitstreams: 2 DISSERTAÇÃO ELLEN SEGADILHA_REVISÃO FINAL_.pdf: 1594859 bytes, checksum: 54ef3c18b30fab0a3f3373b62c9089bc (MD5) license_rdf: 0 bytes, checksum: d41d8cd98f00b204e9800998ecf8427e (MD5) Previous issue date: 2017-12-11 / To elaborate proposals and projects of Marketing requires, above all, creativity and innovation, for this, we need to be attentive to what the market demands and be willing to change. In this sense, the proposal of this project is to improve resources with the objective of eliminating waste of time, ideas, unnecessary waiting and other activities that do not add value to the customer that contract our services. For this, we will use Lean Office as a tool that will make us think in a lean way and eliminate wastes in our daily activities that directly impact our deliveries, increasing our competitiveness and efficiency on the FIEAM System. / Elaborar propostas e projetos de Marketing requer, sobretudo, criatividade e inovação, para isto, precisamos estar atentos ao que o mercado exige e estar disposto a mudanças. Neste sentido, a proposta deste projeto é aperfeiçoar recursos com o objetivo de eliminar desperdícios de tempo, ideias, esperas desnecessários e outras atividades que não agregam valor ao cliente que contratam nossos serviços. Para isto, usaremos como ferramenta o Lean Office que nos fará pensar de forma enxuta e eliminar desperdícios em nossas atividades diárias que impactam diretamente nas entregas, aumentando a competitividade e eficiência do Sistema FIEAM.

Submitted by Marcia Silva (marcia@latec.uff.br) on 2016-05-02T20:33:14Z No. of bitstreams: 2 dissert Oydil Cesar de Figueiredo.pdf: 4453669 bytes, checksum: e33d72aa1c70ea37d37ddcdc603b8c51 (MD5) dissert Oydil Cesar de Figueiredo.pdf: 4453669 bytes, checksum: e33d72aa1c70ea37d37ddcdc603b8c51 (MD5) / Made available in DSpace on 2016-05-02T20:33:14Z (GMT). No. of bitstreams: 2 dissert Oydil Cesar de Figueiredo.pdf: 4453669 bytes, checksum: e33d72aa1c70ea37d37ddcdc603b8c51 (MD5) dissert Oydil Cesar de Figueiredo.pdf: 4453669 bytes, checksum: e33d72aa1c70ea37d37ddcdc603b8c51 (MD5) Previous issue date: 2015-11-30 / O presente trabalho descreve o processo de gestão de melhoria das operações produtivas de fabricação, apresentando um caso prático de aplicação do conceito de produção com foco na eliminação dos desperdícios em uma indústria automotiva. O exemplo aludido relata o processo de planejamento, execução, manutenção e controle de uma sequência de três projetos de melhoria de uma célula de montagem de uma indústria de autopeças, situada na região Sul Fluminense no Rio de Janeiro, entre os anos de 2008 e 2014. A pesquisa teve o objetivo de estudar os métodos e ferramentas Lean Manufacturing na indústria de autopeças identificando os fatores restritivos e facilitadores no processo de aplicação dessa filosofia. Com os dados coletados foi possível verificar vantagens e desvantagens da utilização de diferentes conceitos logísticos, distintas configurações de trabalho padronizado e layout. Por meio de uma revisão documental e uma pesquisa-ação, verificaram-se ganhos significativos ao adotar os conceitos propostos, elevando a produtividade da linha estudada em 92%, quando comparado com o ano inicial, demonstrando-se que as técnicas propostas efetivam-se em vantagem estratégica competitiva em relação a outras empresas concorrentes que trabalham sob a ótica da produção em massa. Como resultados adicionais, a pesquisa fornece informações sobre a sequência de uso das ferramentas oferecendo um auxílio para empresas que buscam a implantação dessa filosofia, disseminando, assim, o conhecimento sobre a filosofia Lean Manufacturing / This study describes the continuum improvement process of productive manufacturing operations, showing an applying case of the concept of production with a focus on eliminating waste in an automotive industry. The example used describes the process of planning, execution, maintenance and control of a sequence of three improvement projects in one assembly line of an automotive parts industry, located in the Rio de Janeiro, between 2008 and 2014. The research aimed to study the methods and Lean Manufacturing tools in the automotive industry by identifying the blocks and facilitators factors in this philosophy application. With the collected data were verified advantages and disadvantages of using different logistics concepts, different standardized work settings and layout. Through a documentary review and action research, have been checked significant gains by adopting the proposed concepts, increasing line productivity by 92%, when compared with the initial year, showing that the applied technical become more effective than the companies that work as pushed production. As additional results, the survey provides information on the use sequence of tools offering support to companies that are implementing this philosophy

The study as detailed in this report is performed in the South African (SA) automotive industry and is aimed at outlining key management elements to be focussed on in order to improve and ensure sustainable continuous improvement initiatives in the form of Lean Manufacturing implementation efforts within a paint shop environment. The organisation being researched is located in Uitenhage which is situated just outside Port Elizabeth (PE) in SA. It is an original equipment manufacturer (OEM) for passenger vehicles and supplies vehicles for both the local and international markets. Further, as part of their business strategy, the organisation also manufactures and supplies automotive parts to the local and international markets. In this study, emphasis will be placed on issues which need to be addressed in order to effectively sustain continuous improvement initiatives in the form of Lean Manufacturing implementation being pursued within the organisation.

This article examines the problem of an increase in product returns for a company that produces plastic films for flexible packaging. Among the factors that have resulted in the increase of returned products are defects in the films caused by the poor manipulation of materials and, above all, the hard point in the coils caused by excessive extruder preparation time, causing the extrusion head to overheat as well as uneven extrusion. Extrusion is a key process in the production of plastic materials as it transforms polypropylene and additives into plastic sheets. The delay in the preparation time caused by machine operators leads to the overheating of the extrusion head and, therefore, defective products that are ultimately returned to the company by customers. In order to confront this problem, a proposal was developed using the SMED tool of Lean Manufacturing in order to reduce the preparation time of the extruder and to increase the productivity of the company. For the validation of the proposal, we simulated the system to determine the resulting reduction in extruder preparation time.

Elaborar propuestas de mejora en el área de producción de una fábrica de snacks a fin de aumentar la capacidad de la planta por medio del incremento de sus dos principales cuellos de botella (Capacidad de envasado y producción de productos intermedios) utilizando las herramientas Lean, la correcta gestión de procesos e investigación de las operaciones y así se reduzcan las entregas pendientes de productos terminados al área comercial. / Improvement of productivity in a snacks factory in the production area in order to increase the capacity of the plant through the increase of its two main bottlenecks (packaging capacity and production of intermediate products) using the Lean tools, the correct management of processes and research of operations to reduce the pendings of finished products to the commercial area.

M.Tech. (Operations Management) / The research is about the application of lean manufacturing tool known as manufacturing kaizen in order to improve a work process at . The company is based in Kempton Park, South Africa, used as a case study to evaluate the benefit of manufacturing kaizen at a specific industrial concern. The research demonstrated how manufacturing kaizen when used appropriately can help APSAP PTY LTD to eliminate waste, have better inventory control, short process cycle times, and better overall financial and operational procedures. The goal was to reduce the identified waste using manufacturing kaizen tool. Waste reduction eventually reduced the cycle time of the work process. The primary objective of the thesis was to study and analyze the cylinder preparation process in APSAP PTY LTD. The process activities were captured, then analyzed using the process map. The secondary objective was to identify waste in the process. Major businesses in South Africa have been trying to adopt new business initiatives in order to stay competitive. One way to increase this is to apply proper manufacturing strategy and use of lean manufacturing or continuous improvement tools to achieve business objective which is to stay competitive and to increase profit. The research addresses the application of a lean manufacturing tool called manufacturing kaizen. Manufacturing kaizen refers to a technique used for improving a work process by the eliminating waste within that process in the organization. It is one of the improvement tools that focus on cost reduction by eliminating non-value added activities. Kaizen achieves the elimination of waste by empowering people with tools and a process to uncover improvement opportunities and make change. Participants are key aspect in implementing the manufacturing kaizen event, since they are the people directly involved. Identifying the key people that will be used in the manufacturing kaizen event is very crucial for the success of the event. Any changes or improvements of the process will have direct impact to the people. It is important that people who are directly affected by change become part of the process and feel empowered. Kaizen understands waste to be any activity that is not value adding from the perspective of the customer. The research unpacks manufacturing Kaizen and looks into its qualitative nature and its application within a working environment and how it influence productivity. It also investigates how this tool can be applied in a process or chemical industry and the benefits it can provide to an organization. The initial step in the approach was to outline data collected and examining techniques used to collect the data. The researcher carried out direct observation as he was physically present, and personally monitored what was taking place. The results show that labor productivity can be improved over time after the introduction of manufacturing kaizen. It concludes that with the introduction of manufacturing kaizen, transformation at workplace can be established leading to productivity improvement within an organization. The research has shown that with the proper use of manufacturing kaizen , waste reduction can be achieved.

Central to the sustainable and competitive growth of the South African construction industry is a predictable cash flow through on time payment by clients to contractors. However, chronic late payments, a recurring problem in the industry, especially in the public sector, is bringing untold hardship to contractors by derailing their competitiveness and also eroding the trust among the supply chain partners to the extent that some firms end up closing business in the industry. The situation is viewed from the lean construction perspective as an obstacle that is preventing the accrual of the required value to project parties in the construction industry. This research addresses the causes of late payments to contractors and the role of the quantity surveyor (QS) in terms of influencing early payment from a lean construction perspective. A mixed method approach was used for compiling the primary data for the study. Sequentially, one hundred and two (102) quantitative and twelve (12) interview questionnaires were administered to selected contractors and construction professionals working predominantly on public sector projects. The findings revealed that the approval process for evaluation and certification by the client- appointed agent and intermediary institutions is taking longer than contractually allowed, with parties independently undertaking their evaluation prior to the certification date. This is found to be adverse to achieving consensus on the values of the works for authorisation. Other significant barriers are the lack of funds to authorise payment, random auditor general’s documentation changes, lack of administrators’ system integration and capacity to handle cyclical payment processing. Also, contractors have been found to be in default of timeously submitting complete claim documents. It is therefore recommended that the client agents should partner with the contractor in regular design and documentation reviews, arranging the payment process and should also meet jointly to prepare monthly evaluations. In addition, contractors should be mentored from the onset of the project regarding all the necessary documentation and supporting documents that will be required by the client to ensure that payment approvals are not delayed. The payment authori-sation agent’s capacity should be enhanced through training and improved powers as a singular point of control to perform efficiently and their systems and processes should be integrated to ensure that all parties are implementing the same protocols.