Lean Six Sigma is a method used to improve the quality and efficiency of processes by reducing variation and eliminating wastes (non-value added activities) in an organisation. The concept of combining the principles and tools of Lean Enterprise and Six Sigma has been discussed in the literature. The majority of Lean Six Sigma applications in private industry have focused primarily on manufacturing applications. The literature has not provided a framework for implementing Lean Six Sigma programmes in non-manufacturing or transactional processes like those in the Entertainment Media industry. The Saudi Broadcasting Corporation (SBC), like many other industries in Saudi Arabia, has high occupational safety risks, such as electric, fire and fall hazards which often occur in the media workplace. These risks are considered very costly and affect productivity and employee morale in general. The main objective of this research is to provide a synergistic approach to integrating occupational health and safety programmes and Lean Six Sigma tools using the DMAIC (Define-Measure-Analyse-Improve-Control) problem-solving method to strengthen and assure the success of safety programmes in the Saudi Broadcasting Corporation (SBC). This research identifies the roadmap (i.e. activities, principles, tools, and important component factors) for applying Lean Six Sigma tools in the media industry. A case study addressing the safety issues that affect employees’ performance within the Saudi Broadcasting Corporation (SBC) TV studio is used to validate work outlined in this research. Furthermore, the Bayesian Belief Networks (BBN) method is used to understand the probability occurrence of safety hazards. The application of the Taguchi Experimental Design method and other Lean Six Sigma tools, such as Cause and Effect diagrams, Pareto principles, 5S, Value Stream map, and Poka-Yoke have been incorporated in to this research. The application of Lean Six Sigma DMAIC problem-solving tools resulted in significant improvement in safety within SBC. The average electrical hazard incident decreased from 2.08 to 0.33, the average fire hazard incident decreased from 1.25 to 0.08, and the average fall hazard incident decreased from 3.42 to 0.17. The research has important implications for the company and its employees, with positive outcomes and feedback reported by top management, the senior technicians, and experts. The research improved the safety by reducing electrical, fire and fall risks. The Safety training sessions are one of the most significant factors that improve their safety awareness. It is observed that Lean Six Sigma problem-solving tools and methods are effective in the Saudi Broadcasting Corporation (SBC).

Este trabalho propõe diretrizes para avaliar sistemas de gestão de poka-yokes (SGPK). As diretrizes foram desenvolvidas após revisão da literatura e estudos de caso destinados à identificação de boas práticas em organizações do ramo metalúrgico, metal-mecânico e automotivo. Em seguida, as diretrizes foram refinadas por meio de um estudo de caso no qual elas foram aplicadas para a avaliação de sete sistemas poka-yokes em uma empresa que utiliza práticas de produção enxuta (PE). As diretrizes propõem que os poka-yokes sejam avaliados com base em um conjunto de categorias (viabilidade econômica, gestão visual, manutenção, projeto e operação, estabilidade da produção e controle de qualidade), que são desdobradas em trinta características passíveis de avaliação. A aplicação das diretrizes no estudo de caso permitiu concluir que: (a) alguns dispositivos entendidos pelas empresas como poka-yoke podem estar distantes dos atributos necessários para caracterizar os mesmos como sistemas poka-yokes; (b) o avaliador precisa ter conhecimento técnico do processo em que o poka-yoke está instalado; (c) as diretrizes propostas podem ser utilizadas como subsídio para o desenvolvimento de novos sistemas poka-yokes; (d) a aplicação das diretrizes tende a ser mais útil para empresas que tem iniciativas de PE implementadas, visto que estas têm ênfase na redução de perdas e, se possuírem mapas de fluxo de valor, podem visualizar o impacto sistêmico de poka-yokes instalados em operações específicas. / This study presents guidelines to evaluate a management poka-yoke system. A literature review and the best practices review in organizations of branch metallurgy, metalworking and automotive preceded the development of the guidelines. Also, a case study was carried out with seven poka-yoke systems to validate the guidelines development in a company that uses lean production practices. The guidelines propose that poka-yoke systems be evaluated on a set of categories (economic viability, visual management, maintenance, design and operation, production stability and quality control), that are unfolded in 30 features capable of evaluation. The application of guidelines in the case study allowed to conclude that: (a) some devices understood by companies as poka-yoke may be far from the attributes necessary to feature then as poka-yoke systems; (b) the evaluator needs to have technical knowledge about the process where the poka-yoke is installed; (c) the guidelines proposed can be used as allowance for the development of new poka-yoke systems; (d) the application of the guidelines tends to be more useful for companies that have lean production initiatives implemented, because they develop efforts to combat wastes and, if they have value stream maps, they can see the systemic impact by poka-yoke systems in specifics operations.

Este trabalho propõe diretrizes para avaliar sistemas de gestão de poka-yokes (SGPK). As diretrizes foram desenvolvidas após revisão da literatura e estudos de caso destinados à identificação de boas práticas em organizações do ramo metalúrgico, metal-mecânico e automotivo. Em seguida, as diretrizes foram refinadas por meio de um estudo de caso no qual elas foram aplicadas para a avaliação de sete sistemas poka-yokes em uma empresa que utiliza práticas de produção enxuta (PE). As diretrizes propõem que os poka-yokes sejam avaliados com base em um conjunto de categorias (viabilidade econômica, gestão visual, manutenção, projeto e operação, estabilidade da produção e controle de qualidade), que são desdobradas em trinta características passíveis de avaliação. A aplicação das diretrizes no estudo de caso permitiu concluir que: (a) alguns dispositivos entendidos pelas empresas como poka-yoke podem estar distantes dos atributos necessários para caracterizar os mesmos como sistemas poka-yokes; (b) o avaliador precisa ter conhecimento técnico do processo em que o poka-yoke está instalado; (c) as diretrizes propostas podem ser utilizadas como subsídio para o desenvolvimento de novos sistemas poka-yokes; (d) a aplicação das diretrizes tende a ser mais útil para empresas que tem iniciativas de PE implementadas, visto que estas têm ênfase na redução de perdas e, se possuírem mapas de fluxo de valor, podem visualizar o impacto sistêmico de poka-yokes instalados em operações específicas. / This study presents guidelines to evaluate a management poka-yoke system. A literature review and the best practices review in organizations of branch metallurgy, metalworking and automotive preceded the development of the guidelines. Also, a case study was carried out with seven poka-yoke systems to validate the guidelines development in a company that uses lean production practices. The guidelines propose that poka-yoke systems be evaluated on a set of categories (economic viability, visual management, maintenance, design and operation, production stability and quality control), that are unfolded in 30 features capable of evaluation. The application of guidelines in the case study allowed to conclude that: (a) some devices understood by companies as poka-yoke may be far from the attributes necessary to feature then as poka-yoke systems; (b) the evaluator needs to have technical knowledge about the process where the poka-yoke is installed; (c) the guidelines proposed can be used as allowance for the development of new poka-yoke systems; (d) the application of the guidelines tends to be more useful for companies that have lean production initiatives implemented, because they develop efforts to combat wastes and, if they have value stream maps, they can see the systemic impact by poka-yoke systems in specifics operations.

Este trabalho propõe diretrizes para avaliar sistemas de gestão de poka-yokes (SGPK). As diretrizes foram desenvolvidas após revisão da literatura e estudos de caso destinados à identificação de boas práticas em organizações do ramo metalúrgico, metal-mecânico e automotivo. Em seguida, as diretrizes foram refinadas por meio de um estudo de caso no qual elas foram aplicadas para a avaliação de sete sistemas poka-yokes em uma empresa que utiliza práticas de produção enxuta (PE). As diretrizes propõem que os poka-yokes sejam avaliados com base em um conjunto de categorias (viabilidade econômica, gestão visual, manutenção, projeto e operação, estabilidade da produção e controle de qualidade), que são desdobradas em trinta características passíveis de avaliação. A aplicação das diretrizes no estudo de caso permitiu concluir que: (a) alguns dispositivos entendidos pelas empresas como poka-yoke podem estar distantes dos atributos necessários para caracterizar os mesmos como sistemas poka-yokes; (b) o avaliador precisa ter conhecimento técnico do processo em que o poka-yoke está instalado; (c) as diretrizes propostas podem ser utilizadas como subsídio para o desenvolvimento de novos sistemas poka-yokes; (d) a aplicação das diretrizes tende a ser mais útil para empresas que tem iniciativas de PE implementadas, visto que estas têm ênfase na redução de perdas e, se possuírem mapas de fluxo de valor, podem visualizar o impacto sistêmico de poka-yokes instalados em operações específicas. / This study presents guidelines to evaluate a management poka-yoke system. A literature review and the best practices review in organizations of branch metallurgy, metalworking and automotive preceded the development of the guidelines. Also, a case study was carried out with seven poka-yoke systems to validate the guidelines development in a company that uses lean production practices. The guidelines propose that poka-yoke systems be evaluated on a set of categories (economic viability, visual management, maintenance, design and operation, production stability and quality control), that are unfolded in 30 features capable of evaluation. The application of guidelines in the case study allowed to conclude that: (a) some devices understood by companies as poka-yoke may be far from the attributes necessary to feature then as poka-yoke systems; (b) the evaluator needs to have technical knowledge about the process where the poka-yoke is installed; (c) the guidelines proposed can be used as allowance for the development of new poka-yoke systems; (d) the application of the guidelines tends to be more useful for companies that have lean production initiatives implemented, because they develop efforts to combat wastes and, if they have value stream maps, they can see the systemic impact by poka-yoke systems in specifics operations.

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / Small and medium toilet manufacturing businesses in Peru face significant problems such as low productivity because of a high rate of production losses. To address this issue, the present study proposes the application of a lean manufacturing technique, such as the Poka-Yoke model, which improves the production flow within the company by implementing a transportation cart with a safety system to help reduce material falls during the manufacturing process. The results showed a 24% increase in productivity and reduction in problems of damaged products that did not meet quality standards, thus preventing their subsequent reprocessing. / Revisión por pares

This thesis deals with design of the reflector assembly line. The document contains the analysis of the customer requirements sheet. In short there is written how to put the parts of the reflector together. The Poka-Yoke method is properly described in this work too. This method is used to design of the actions, which are trying to decrease the risk level of wrong reflector composition as low as it is possible. FMEA and PFMEA methods are explained in theory. There is the plan how to make the analysis too. The instrumentation of one part of the line is designed according to this analysis and according to the customer requirements. The OEE pointer is used to test the right effect of the Poka-Yoke method. The next aim of this thesis is to compare chosen PLCs for control of the assembly line and to choose one of them. On the base of the analysis there is designed the control program in the flowcharts form. One part of this thesis is focused on design of the visualization for the chosen operational panel.

The manufacturing companies are faced to the strong pressure to decrease the production costs. They are therefore forced to optimize the manufacturing processes and to increase their efficiency. The ideal way to increase the productivity is to optimize the manufacture by increasing the efficacy of the equipment, material, working hours and other sources of finding out causes of wasting in production, it means to abolish the causes of making mistakes.

This thesis deals with proposal of assembly line modification for production of electromagnetically controlled pneumatic valves. The beginning of this thesis is dedicated to the theoretical study the most common Poka-Yoke systems, which are used for mistake avoiding in assembly process. There is described analytical analysis FMEA, which is used for detection of weak place in process. The next chapter is focused on description of valves manufactured on this assembly line. Main part of thesis is dedicated to proposal for process modification and design solution with choosing of appropriate sensors for some operations. There are created documents as a flow-chart for control algorithm, FMEA and process flow-chart for proposal according to automotive standard and estimated budget with counted payback period for whole project in last part.

Este trabajo de investigación propone diseñar un proceso para la recuperación de separador de cartón prensado utilizado en el paletizado de botellas, a fin de reducir los costos logísticos de la empresa, materia de estudio. El gasto actual, debido a la reposición del material, re selección y fletes; es mayor a los $500 K USD (3.96% de la facturación total anual del 2018). Por ello, se detectó la necesidad de contar con un proceso estructurado que minimice los gastos generados. Haciendo uso herramientas tales como el SIPOC, AMEF, realización de comité con los actores involucrados, diagrama de Ishikawa y análisis de los 5 por qué, se identificaron las causas raíces del proceso actual, las que han sido atacadas en la propuesta para la recuperación del separador de cartón prensado. Se ha sugerido elaborar un procedimiento de plan de compras, uso de poka yoke con defectos críticos para la re selección del separador de cartón prensado. Asimismo, se ha recomendado que, al ser un proceso soportado por actividades manuales, sería conveniente incluir un plan de incentivos que ayude a mantener el interés en lograr los objetivos del proceso y someter las actividades que requieren control a un estudio de métodos y tiempos, a fin de incrementar la productividad. Al implementar esta propuesta se espera aumentar el porcentaje de recuperación en 15% (aproximado) con respecto al año anterior (2018) generando ahorros por encima de los 100K USD. / This research paper proposes to design the process for the recovery of pressed cardboard separator used in the palletizing of bottles, in order to reduce the logistic costs of the company, subject of study. The current expense due to the replacement of material, re-selection and freight is greater than $ 500K USD (3.96% of the total annual turnover of 2018). Therefore, the need for a structured process that minimizes the expenses generated was detected. By using tools such as SIPOC, AMEF, carrying out a committee with the actors involved, Ishikawa diagram and analysis of the 5 whys, the root causes of the current process were identified, which have been attacked in the proposal for the recovery of the pressed cardboard separator. It has been suggested to develop a purchasing plan procedure, to use poka yoke with critical defects for the re-selection of the pressed cardboard separator. It has also been recommended that, since it is a process supported by manual activities, it would be convenient to include an incentive plan that helps to maintain interest of the people involve in these activities in achieving the objectives of the process and submit the activities that require control to a study of methods and times, in order to increase productivity. By implementing this proposal, it is expected to increase the recovery percentage by 15% (approximated) compared to the previous year (2018) generating savings above USD 100K. / Trabajo de investigación

<p>In today‟s manufacturing environment, different parts manufactured in-house and bought from suppliers are often assembled together into a finished product. Competition has made it very important for companies to deliver a customized product on a promised date. However, when inventory items are missing at the time of production, lead times for products become uncertain and this makes it difficult to fulfill a customer order on the promised date. It is thus important to explore the causes of missing items at the time of production in order to solve such a problem. This Master of Science thesis carried out through a case study at Fläkt Woods in collaboration with Jönköping University is about the problem of not finding specific inventory items in the locations specified by the computer system. It is delimited to inventory items which are physically within the company premises or which according to the computer system are within the premises of the company. The questions at issue have been what the causes of the problem of missing items within the company are and how to effectively reduce the problem. The thesis has been carried out over an entire academic semester as a full-time work in the company. The sources of the problem have been found to be the result of the work procedure, the underlying software used during work (the in-house developed ERP system), stealing from orders, ineffective barcode scans, re-sequencing at the component manufacturing department (called pre-manufacturing in the company) due to the need to fulfill multiple objectives, set-up times at the component manufacturing department and human errors among others. The suggestions given include: modification of the work procedure and the underlying software used at work, increasing effective scanning and using some checks at critical points in the material flow. Areas for further research are given to further reduce the impact of the problem on the production system.</p>