En la actualidad el mundo Retail ha tenido que diversificar y explorar diferentes propuestas de formatos en base a las necesidades de los clientes. Se han ido desarrollando tiendas físicas para clientes tradicionales pero existe un mercado online que en el mundo ha ido tomando una importante participación y que en el Perú está en crecimiento. Por este motivo el presente trabajo de investigación se busca proponer mejoras en el negocio Ecommerce o venta online en el proceso de multipicking, asegurando un proceso que agregue valor al cliente y a la empresa eliminando los desperdicios o mudas que se presenten utilizando la metodología de Lean Service y las herramientas de análisis necesarias para identificar las causas que generan las problemáticas identificadas como pedidos incompletos, demora en la entrega de los pedidos o las demoras en las reversiones de los cliente. El primer capítulo abordará los antecedentes, la teoría y la metodología de mejora seleccionada. El segundo capítulo presenta la situación actual de la empresa, el diagnóstico de la problemática en el proceso multipicking. En el tercer capítulo se determina la asignación de cada herramienta para la solución a las problemáticas detectadas y se presenta propuestas de mejora. El cuarto capítulo se muestra los resultados de la implementación de las mejoras y el análisis del impacto de la implementación aplicando la matriz de Leopold. Asimismo se muestra un análisis financiero del despliegue del proyecto en la empresa. / Currently, the Retail world has had to diversify and explore different proposals based on the needs of customers. Physical stores have been developed for traditional customers but there is an online market that in the world has been taking an important participation and that in Peru is growing. For this reason, the present research seeks to propose improvements in the Ecommerce business in the multipicking process, ensuring a process that adds value to the client and the company, eliminating the waste that are presented using Lean Service methodology and the necessary analysis tools to identify the causes that generate the problems identified as incomplete orders, delay in the delivery of orders or delays in customer reversals. The first chapter will deal with the background, the theory and the selected improvement methodology. The second chapter presents the current situation of the company, the diagnosis of the problem in the multipicking process. In the third chapter, the application of each tool for the solution to the problems detected is determined and proposals for improvement are presented. The fourth chapter shows the results of the implementation of the improvements and the analysis of the impact of the implementation applying the Leopold matrix. It also shows a financial analysis of the deployment of the project in the company. / Tesis

Estágio realizado na Inapal Plásticos, S.A. e orientado pelo Eng.º António Dionísio / Tese de mestrado integrado. Engenharia Metalúrgica e de Materiais. Faculdade de Engenharia. Universidade do Porto. 2010

La presente investigación expone los resultados de la implementación de un Proyecto Lean Manufacturing, por medio del cual se logró la reducción de los costos generados por no conformidades del proceso de costura. Mediante el análisis realizado se identificó como principales desperdicios: los defectos, evidenciados en el alto índice de reprocesos y los recursos mal utilizados, evidenciados en el estándar de personal que realiza inspección 100% al final de los módulos de costura y el personal destinado a realizar los reprocesos. Dichos desperdicios a su vez tenían como origen la falta de estandarización de métodos de trabajo para el personal de costura, un sistema de control de calidad sesgado al “control” y no al aseguramiento de la calidad en el proceso y a la falta de un espíritu de mejora continua. Es por ello que el proyecto propuso la implementación de la estandarización, técnicas de calidad y la creación de dispositivos Poka Yoke, todas herramientas Lean, que a su vez están sostenidas por Kaizen como parte de la mejora continua. A partir de la implementación de dichas herramientas se ha logrado mejorar los indicadores de %reprocesos, pasando de 17.5% a 4.4%; eficiencia, pasando de 65% a 70%, los costos por sobretiempos del personal de calidad de S/12,013 a S/5,082 y la eliminación de las concesiones. Cada uno de estos indicadores se ha valorizado teniendo como resultado final del proyecto un TIR de 50% y un VAN de $14,479, lo que evidencia la rentabilidad de la implementación. Palabras clave: Lean Manufacturing, No conformidades, desperdicios, estandarización, mejora continua, Poka Yoke, TIR, VAN. / --- This research presents the results of the implementation of a Lean Manufacturing Project, whereby reducing the costs generated by reprocessing the stitching process is achieved. Through the analysis was identified as the main waste: defects evident in the high level of rework and resources misused and reflected in the standard of personnel performing 100% inspection at the end of modules sewing and personnel for perform the rework. Those by-turn had its origin in the lack of standardization of working methods for personal stitching, a system of quality control biased "control" rather than the quality assurance in the process and the lack of a spirit of Continuous improvement. That is why the project proposed the implementation of standardization, quality techniques, creating Poka Yoke devices, all Lean tools, which in turn are supported by Kaizen as part of continuous improvement. Since the implementation of these tools has improved indicators rework%, from 17.5% to 4.4%; efficiency from 65% to 70%, the costs for staff overtimes quality S / 12,013 S / 5,082 and removing concessions. Each of these indicators has been recovered with the final result of a TIR project 50% and VAN of $ 14.479, which shows the profitability of implementation. Keyswords: Lean Manufacturing, Nonconformities, waste, standardization, continuous improvement, Poka Yoke, TIR, VAN. / Tesis

Proyecto sobre la eliminación de productos no conformes obtenidos en la fabricación de repuestos metálicos, nos muestra la viabilidad de su ejecución en base a la investigación realizada en una PYME de la ciudad de Lima, que permitió detectar la existencia de operaciones defectuosas y actividades que no generan valor en su cadena productiva. Mediante la implementación de las mejoras que se proponen en el presente trabajo, se reducen los rechazos por productos no conformes y se mejora el nivel Six Sigma en cuanto a la calidad. Para su implementación se requerirá una inversión de S/.229,094.25, la cual generará en el primer año ahorros de S/.92,566.45. Mediante la simulación en el software Arena, se valida la implementación funcional de la propuesta, y mediante una evaluación financiera, se llega a obtener un valor del VAN de S/. 62,626.45, y de 19.54% en la TIR, , confirmando su factibilidad económica. / Project on the elimination of non-conforming products obtained in the manufacture of metallic spare parts, shows us the feasibility of its execution based on the research carried out in an SME in the city of Lima, which allowed to detect the existence of defective operations and activities that do not generate value in their productive chain. / Trabajo de Suficiencia Profesional

MARTINOVSKÝ Peter: Identification and elimination of errors in the productions of bearings Diploma thesis elaborated in frame of engineering studies branch by means of identifying and eliminating errors in the production process of the clutch bearings using FMEA and Poka – Yoke. With the contribution of these methods are identified and eliminated the five most serious errors, which value of RPN exceeded a limits demanded by customers.

In the bakery industry, it is sought to have zero defective products. It is in the packing; where it is evident, as the last area of the production chain, all the defects generated. Therefore, a combined redesign method is proposed, which consists in the use of Economy of Movement, Ergonomics, Poka Yoke and Method Engineering to reduce defective products in SMEs in the bakery industry. The losses of these generate a reduction of 29.50% for crushed bread and 19.67% of bread on the floor, reducing with the use of this method to 16.20% and 8.38% respectively.

This report is the result of a bachelor thesis project conducted as the final part of the education in Innovation technique and Design at Karlstad University. The project itself was carried out at Tetra Pak, Lund and consisted of re-designing a component used in packaging machines, with the purpose of making it fool proof in terms of assembly. The mis mounting of this component could lead to inferior sealing quality in packages produced and in worst case leakage and spoiled content. The issue of the mis mounting has been raised by several customers and Tetra Pak is looking for a solution to improve the mounting.   The methods used in this project are common in product development, such as the use of a design specification, generating solutions by various brainstorming methods and evaluating these concepts by different forms of matrices. In addition to common product development methods, other suiting methods such as CAT (Consensual assessment technique) has been used and theory in Poka-yoke solutions as well as Cognitive ergonomics has been studied. In the pre-studies, a rather wide study of different sources has been made to gather information on this technically advanced target component and converged them all by the principles of data triangulation. By involving user centred design theory, the entire methodology also extends to using the view of the users in all steps along the way. The resulting solution has been filed as a report of invention by Tetra Pak along with two other concepts which were deemed valuable for the company by the supervisor at Tetra Pak. This proposed concept is not only physically impossible to misplace, it also displays by colour marking how it is to be placed and reminds the assembler of the process by nearby instructions. The resulting CAD model shows this solution as technically fit for the machinery and a simple mock-up of the physical function of the solution shows how it would be impossible to mount incorrectly. The project resulted in 39 different concepts of various function, documented in an idea archive. This project has developed a proposed Poke-yoke solution which matches the product specification set by the company as well as two other solutions deemed of value by the company in terms of future use. The proposed use of the main solution shows potential in solving the issue at a reasonable expected cost while theoretically improving user cognition. The solution also requires very little physical change in the component and surrounding machinery, thus giving it great potential for retrofit ability.

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / The Peruvian export supply is primarily based on the segment of dressings and condiments. This paper seeks to adapt lean manufacturing tools using Poka-Yoke techniques and process standardization, which may align with existing processes to prevent production errors. This combination of tools is expected to reduce the percentage of waste generated throughout the condiment production process. Subsequent to an initial evaluation of the current method combined with the application of both the tools, 11.4% waste reduction was ultimately reported. / Revisión por pares

Examensarbetet utfördes på Volvo Construction Equipments anläggning i Hallsberg. Projektet utgick på att studera materialhanteringen i tankmonteringen. VCE monterar idag cirka 50 hydraul- och bränsletankar om dagen och har uppemot 20 olika typer av tankar för Volvos hjullastare och ramstyrda dumprar. Tankarna monteras i ett rum med renhetsklassning vilket utgör svårigheter i hur bland annat material får hanteras och förvaras i rummet. Idag förvaras materialet för dessa tankar i monteringslokalen i de fyra monteringsstationerna. Monteringsstationerna har begränsat med plats för material och behöver återfyllas ifrån mellanlagret utanför lokalen. Kundavvikelser på grund av fel monterade tankar är ett problem och kan ha koppling till materialet. I Volvo CE:s ständiga utvecklingsarbete med effektivitet och kvalitetssäkring i fokus ifrågasätts dagens läge inom materialhantering och kvalitetssäkring. Volvo CE misstänker att läget idag inte är optimalt och önskar en utredning på hur materialhanteringen kan effektiviseras för framtida produkter med hänsyn till renhetssklassningen samt hur monteringsfel kan minimeras med eventuella hjälpmedel.  Efter observationer samt samtal med montörer och ansvariga kunde en nulägesbeskrivning skapas i syfte få en överblick över problemområdet och inhämta kunskap om projektets avgränsningar. Utifrån observationer och intervjuer ur ett Lean-perspektiv samt med Lean-verktyg utformades en nulägesanalys. Slöserier identifierades med 7+1 metoden, tankmonteringen visade brister i 5S arbetet. Rotorsaksanalyser på 7+1 slöserierna och bristerna i 5S utfördes och förbättringsmöjligheter visades.  Kittning som med i materialförsörjningen presenterades som förbättringsförslag där materialhanteringen skulle minimeras för montörerna vilket skulle leda till ökat fokus och ökad kvalitet på monteringen. Kittning eliminerar även behovet till att förvara material i monteringslokalen. VCE rekommenderas att i det fortsatta arbetet studera följande: •    Hur kittning kan implementeras på olika nivåer i tankmonteringen•    Poka Yoke. Hur risken för felplock eller felmontering kan minimeras med hjälp om konstruktioner eller färgkodningar•    Digitalisering av monteringslokalen. Datorer vid varje bås med ständigt uppdaterade monteringsrutiner kan minimera risken för fel. / This thesis was carried out at Volvo Construction Equipment's facility in Hallsberg. The project was based on studying material handling in the tank assembly. VCE currently assembles about 50 hydraulic and fuel tanks a day and has up to 20 different types of tanks for Volvo wheel loaders and dump trucks. The tanks are mounted in a room with purity rating which poses difficulties in how materials may be handled and stored in the room, among other things. Today, the material is stored for these tanks in the assembly room of the four assembly stations. The assembly stations have limited space for materials and need to be refilled from the supermarket outside the premises. Customer returns due to faulty assembled tanks are a problem and may be related to the material handling. Volvo CE's continuous development work with efficiency and quality assurance in focus calls into question the current situation in material management and quality assurance. Volvo CE suspects that the situation today is not optimal and asks for an investigation into how material handling can be made more efficient for future products considering the cleanliness-controlled environment and how assembly errors can be minimized with any aids. After observations as well as conversations with fitters and managers, a present-mode description could be created in order to get an overview of the problem area and gain knowledge of the project's boundaries. Based on observations and interviews from a Lean perspective and lean tools, a current situation analysis was designed. Wastes were identified using the 7+1 method, the tank assembly showed shortcomings in the 5S work. Root cause analyses of 7+1 waste and the shortcomings of 5S were carried out and opportunities for improvement were demonstrated. . Kitting presented as an improvement proposal in which material handling would be minimized for fitters, which would lead to increased focus and increased quality of assembly. Kitting also eliminates the need to store materials in the assembly room. VCE is recommended to study the following: •    How Kitting can be implemented at different levels in the tank assembly•    Poka Yoke. How the risk of error picking or faulty assemblies can be minimized by using new designs or color codings.•    Digitization of the assembly room. Computers at each booth with constantly updated assembly routines can minimize the risk of errors.

This PhD project aims to develop a cost modelling system to support lean product and process development. The system enables the designers to assess the design along with associated manufacturing processes and provides decision support at an early development stage. Design assessment at early development stage can help designers to take proactive decisions, eliminate mistakes and enhance product value. The developed cost modelling system to support lean product and process development incorporates three lean product and process development enablers, namely set-based concurrent engineering, knowledge-based engineering, and mistake-proofing (poka-yoke). To facilitate above explained lean enablers, the system architecture contains six modules, six separate groups of database, a CAD modelling system, and a user interface. The system modules are: (i) value identification; (ii) manufacturing process/machines selection; (iii) material selection; (iv) geometric features specification; (v) geometric features and manufacturability assessment; and (vi) manufacturing time and cost estimation. The group of database includes: (i) geometric features database, (ii) material database, (iii) machine database, (iv) geometric features assessment database, (v) manufacturability assessment database, and (vi) previous projects cost database. A number of activities have been accomplished to develop the cost modelling system. Firstly, an extensive literature review related to cost estimation, and lean product and process development was performed. Secondly, a field study in European industry and a case study analysis were carried out to identify current industrial practices and challenges. Thirdly, a cost modelling system to support lean product and process development was developed. Finally, validation of the system was carried out using real life industrial case studies. The system provides a number of benefits, as it enables designers to incorporate lean thinking in cost estimation. It takes into consideration downstream manufacturable process information at an early upstream stage of the design and as a result the designer performs the process concurrently and makes decisions quickly. Moreover, the system helps to avoid mistakes during product features design, material and manufacturing process selection, and process parameters generation; hence it guides toward a mistake-proof product development. The main feature of the system, in addition to manufacturing cost estimation, is set-based concurrent engineering support; because the system provides a number of design values for alternative design concepts to identify the feasible design region. The major contribution of the developed system is the identification and incorporation of three major lean product and process development enablers, namely set-based concurrent engineering, knowledge-based engineering and poka-yoke (mistake-proofing) in the cost modelling system. A quantification method has been proposed to eliminate the weaker solution among several alternatives; therefore only the feasible or strong solution is selected. In addition, a new cost estimation process to support lean product and process development has been developed which assists above explained three lean product and process development enablers.