Master Thesis studies integrated Supply Chains and their particularities in the automotive industry and searches for ways how to rationalize them. It aims to find means how to make the lead times shorter, with the focus on an automobile producer in an effort to increase its competitiveness. It is geared to identify points in its Supply Chain, where flaws and errors or delays in the process of customer order fulfillment might occur. It also concentrates on the possibility of managing customer demand. The Thesis then investigates circumstances that especially in the automotive do play a role and influence the lead time. Based on the established information and facts it proposes measures that resolve this problem with regard to current trends in the industry and also consider the requirements and expectations of customers buying a new car.

Intention of this work is to introdukce ideas of lean enterprise in general but also on concrete example of company BENTELER, ČR s.r.o. and take a think on influences and difficulties. Dissertation is divided into theoretical part which describing basic methods and principles of lean enterprise and practical part. In practical part I am introducing company BENTELER, ČR s.r.o. and actions to establish lean production on concrete example in plant Chrastava.

Orientador: Antonio Batocchio / Tese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-18T16:55:13Z (GMT). No. of bitstreams: 1 Calado_RobisomDamasceno_D.pdf: 10324575 bytes, checksum: bd7eff1020aca7d34e222fde5fbd037d (MD5) Previous issue date: 2011 / Resumo: O objetivo do trabalho é diagnosticar e identificar pontos fortes e fracos da gestão da produção em empresas de diferentes segmentos, visando fornecer subsídios de auxílio nas decisões de investimento, informações estratégicas e oportunidades de melhoria nos processos através da abordagem Lean. A condução do Método de Diagnóstico de Empresa (MDE) deuse através de questionários, entrevistas e Mapeamento do Fluxo de Valor (MFV) no chão de fábrica, permitindo planejar ações para melhor gerenciamento da capacidade dos equipamentos, bem como orientar o Planejamento Hoshin e o Gerenciamento Estratégico de forma mais integrada e sustentável. O estudo resultou em uma avaliação quantitativa do grau de maturidade organizacional da empresa, sendo considerados os conceitos relacionados a Mapeamento de Fluxo de Valor, Produção Enxuta, Gerenciamento da Capacidade, Sistema Grey e Benchmarking Industrial. O estudo visa criar condições para auxiliar as decisões de médio e longo prazo através das definições de processos, projetos e ações alinhadas ao Gerenciamento Estratégico da organização e a abordagem Lean / Abstract: The objective of this work is to diagnose and identify strong and weak points on production management of companies from different segments, to provide help on investment decisions, strategic information and opportunities for processes improvement by the Lean approach. The conduct of the Business Diagnostic Method (BDM) was done by the use questionnaires, interviews and the Value Stream Mapping (VSM) on the factory floor, allowing both the planning of actions to better manage the capacity of the equipment and the guiding of the plan of policy deployment (Hoshin Kanri) in a more integrated and sustainable way. The study resulted in a quantitative assessment of the organizational maturity degree of the company, being considered concepts related to the Value Stream Mapping, the Lean Production, the Management Capacity, the Industrial Benchmarking and the Grey Systems. The study aims to create conditions to support decisions of medium and long term by the definitions of processes, projects and actions allied to with the organization's Policy Deployment and the Lean approach / Doutorado / Materiais e Processos de Fabricação / Doutor em Engenharia Mecânica

The diploma thesis focuses on the implementation of lean production into the selected production section of EKOM company. In the analytical part, the production company will be characterized and the current state of production in the selected section will be described. The practical part of the thesis will be based on the theoretical part and there will be proposals for implementation of lean production elements.

The building industry has issues with efficiency and waste where only 3-20 % of the activities in a process are of value. The production philosophy Lean, has been shown to reduce waste and also increase efficiency. Lean derives from Toyota Production System and involves, among other things, reducing waste, standardizing processes and continuous improvements while maintaining focus on the customer.   To value how Lean a company is, there are different Lean maturity models that can be used. For industrialized housing there has been a lack of a maturity model which can be used to evaluate their Lean maturity. Therefore, the purpose of this study is to develop a Lean maturity model within industrialized housing with production in focus, where developing opportunities are shown for continuing work with Lean.    This study has developed a specific Lean mature model for industrialized housing (LMI) where categories that are relevant for evaluation of the maturity level have been developed. Test of LMI from theory have shown that it works. The companies participating in the study that have an ongoing Lean work consider the categories relevant and accurate, with small changes to function entirely. For the study it can therefore be concluded that an evaluation model for Lean maturity in the industrialized housing can appear according to the reports descriptions. The companies participating in this study have in multiple categories reached different levels. In common there is a lack of methods for distributing and collecting experiences. Furthermore, LMI indicates that Swedish industrialized housing in general have extended understanding about Lean. This can be compared to traditional on-site construction where the efficiency and Lean maturity still in general can be considered low. Lean can therefore be seen as a success factor with waste and continuous improvements in focus. The conclusion of this study shows potential improvements within experience feedback amongst the companies working in industrialized housing.

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 recent years, homegrown SMEs have had low production levels when compared with Chinese garment imports, losing their competitive advantage in the domestic market. SMEs represent 96% of garment companies in Peru and have a positive impact on the creation of jobs. The search for a technique to improve SME output was conducted in various studies; however, the efforts did not bear fruit over time. Thus, this article seeks to improve the low production efficiency in textile and clothing SMEs. Therefore, we proposed a model and validated it in the production area of a denim clothing manufacturing company in Peru. We conducted business diagnostics and found a production efficiency problem. Later, we adapted the Lean production management model to the prevailing organizational culture. The main result was that the company's production efficiency increased from 68% to 71%. Finally, employee commitment, along with the combination of the Lean model and organizational culture, allowed the improvements to stand the test of time after their implementation.

This paper proposes an optimization model aimed at increasing production capabilities at a small-sized textile business dedicated to manufacturing polo shirts, while reducing order fulfillment issues, including incomplete orders and late deliveries. Hence, an assessment identified downtimes from unnecessary transportation travel, time spent looking for materials, and excessive losses due to cutting fabric errors. In this light, the study focused on selecting adaptable tools, such as 5S, Plant Layout, and Method Study, which may help improve production capabilities and address these situations. However, to guarantee that the objectives set forth are being met, the organizational culture must also be identified and improved so that it may serve as the foundation for the optimization model. Then, the proposed model will be validated to determine whether the selected operating tools supported by the strengthening of organization culture contribute to increasing production.

Currently, small- and medium-sized enterprises face order fulfillment issues, thus generating reduced service levels. In addition, these companies are usually not aware of the importance of continuous improvement tools or of training staff as a mitigation strategy for this situation. Within this framework, the authors performed a literature review to compile production models through which downtimes could be reduced. The production model designed therefrom comprises Lean Manufacturing and work study tools within a Change Management approach. This design focuses on model implementation by small companies without requiring large investment, cutting-edge technology, or qualified personnel. Finally, an application case study was conducted in a small textile manufacturing company located at the Gamarra Fashion Center in Lima, Peru. The results that were reported revealed that late order fulfillment instances reduced by up to 18%, which had an impact on downtimes, unnecessary movements, and in-process inventory levels, thus increasing productivity by 85%.

Lean Production är en välkänd filosofi som är väl beprövad inom tillverkningsindustrin men inte inom detaljhandeln. Filosofin bygger på att genom förändringar effektivisera verksamheten genom att minska slöseri av resurser och ständigt arbeta med förbättringar. Forskning visar på att det finns goda skäl till att implementera Lean Production inom livsmedelsbranschen för att effektivisera verksamheten men också öka kundnöjdheten och lönsamheten. Syftet med studien är att skapa en förståelse för hur Lean Production kan påverka den dagliga driften för livsmedelsbutiker. Samt hur verksamheterna ställer sig till Lean Production och vilka möjligheter respektive hinder som finns för implementering. Kan effektivisering, kundnöjdhet och lönsamhet ökas genom Lean Production samt hur ställer sig butiker till filosofin. Studien innefattar därför en studie med en kvalitativ metod i form av intervjuer där en intervjuguide var till hjälp för genomförandet. Resultatet visade att effektivisering är något de flesta arbetar med i viss utsträckning samt att en implementering av Lean Production var möjlig. Däremot brister det i en rad faktorer där fokus bör läggas i sådana fall. Kommunikationen var en återkommande faktor som spelade in till det negativa genom flertalet faktorer samtidigt som det är något det ständigt arbetas med. Tiden var en faktor som uppfattades som en orsak till att fler saker inte fungerade där den positiva ställningen till förändring får ses som en stor nyckel till att implementering inom medelstora livsmedelsbutiker är av intresse och genomförbart. Vilket skulle öka engagemang, kommunikation och kunskap som är en rad viktiga faktorer för en fungerande verksamhet.

Current housing trends point to an increasing interest from homebuyers to demand houses that reflect their personal and unique styles, and which are individually configured according to these needs (NAHB, 2004). These homebuyers in turn are unwilling to settle for standard models that sacrifice what they really want in a home. At the same time this creates pressure on builders who are reluctant to sacrifice production efficiencies by deviating from standard models. Such customization desired by demanding customers can disrupt the entire estimating, production, delivery and management process, making it even more difficult to manage homebuilding efficiently and effectively. The question faced by homebuilders in this conditions is, how to manage this trade-off and deliver exactly what homebuyers want, at reasonable prices and lead times with minimal disruptions in efficiencies. Mass Customization (MC) is an emerging production paradigm that seeks to manage the trade-offs between product variety and mass efficiency, while fulfilling individual customer requirements. The general purpose of this research is to improve the effectiveness and efficiency of housing production through the implementation of mass customization strategies. More specifically, this research focuses on the study of the production system through the application of lean production principles, as an approach to enable mass customization. This study first characterizes how much product choice is currently being offered by U.S. homebuilders and what is the impact of customization on production efficiency; and then focuses on the evaluation of the relationships between mass customization and lean production principles. Results revealed that homebuilders offering increased product choice are likely to suffer poorer labor productivity, greater inventory, higher production costs, more quality issues, less satisfied homebuyers, and lower space efficiency. In general, operational performance deteriorated with an increase in product choice. Therefore, industrialized housing manufacturers have not reached the ideal of mass customization and are paying a price for offering more choices to their customers. Homebuilders could mitigate these challenges by using lean concepts. In general, case studies showed that product choice does not necessarily make the implementation of lean concepts more difficult. Some lean concepts, like workload balancing and standardizing tasks, clearly facilitated the handling of product choice. Other lean concepts, like creating a continuous process flow, can be made to work well, even with increased choice. Case study results suggested that good concepts for lean (e.g., efficient continuous flow, effective pull system, workload leveling, defect-free processes, standard tasks, good visual controls, and reliable technology) were also good concepts for (or easily accommodated) handling a range of product choice.