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.

Introduction: In today’s global world, supply chain and logistics operations have become far too complicated to be handled by individual firms. Nowadays, it is dealt by logistics and freight solution providing companies. The companies introduce an amount of flexibility for the firms doing their business. The performance of supply chain operations depends upon various dimensions such as location, quality, on-time delivery, dependability and cost. Reducing the operational costs by increasing effectiveness of process helps to gain a competitive advantage. Background: Logistics is a highly labour intensive industry. The primary role of a distribution centre as a supply chain element is to sort and forward the incoming goods(parcels) as effectively as possible within the minimum time. Due to the varied physical attributes of incoming goods/parcels, the sorting process in distribution centres involves different handling techniques. One such technique is the use of a parcel sorter conveyor system, there are various factors based on which the output increases or decreases in such systems. Flexibility is a factor that is seldom compromised, thus failing to operate effectively when volume increases, reduce a competitive advantage for the any distribution centre. Purpose: The purpose is to identify reasons for ineffectiveness during the process and find improvement opportunities which enables a distribution centre to handle more volume on a daily basis. Case: This single case study is carried out at a regional distribution centre aiming to grow regarding the number of suppliers and volume of handled parcels. Findings: The sources of ineffectiveness and improvement opportunities were identified (some of the improvement opportunities are case specific). Discussions: The study provides evidence that errors which are thought to be caused due to human actions can have other root causes, a synergetic approach is suitable in situations where high interdependency of variables exist.   Conclusions: The study has focused on a single case study, conducting the similar type of study with other companies working within a similar environment can provide more generalisable evidence. Improvement should be seen with a mentality of sustaining, with high variability of changes occurring, there should be a focus towards continuous improvement as well.

Main goal of thesis is process analysis of nonconforming products and implementation of the corrective actions which will improve current status. Theoretical part presents history of quality, modern methods in quality, process of nonconforming products, preventive methods used in car industry and also the costs of quality. Practical part presents process analysis of nonconforming products in concrete company and main focus is implementation of the corrective actions. Main point regarding the improvement is upgrading detection system. Upgrade was made on concrete product, which represented huge quality extracosts.

Pappersbruket Fiskeby Board som är placerat i Norrköping tillverkar kartong av 100% returfibrer. Bruket har tillverkat papper i flera århundranden och är en av Europas äldsta tillverkare av papper och kartong. På pappersbruket finns ett underhålls- och reservdelslager som bistår med artiklar till hela företaget. Målet med studien är att ta fram förslag till hur förrådshanteringsprocessen kan förbättras för att göra den mer effektiv. Studien resulterade i 25 stycken förbättringsförslag, dessa förslag delades upp i två delar, de förbättringsförslag som kunde implementeras direkt och de som behövde vidare undersökningar. Vissa förslag täcker flera möjligheter och problem och andra förslag täcker bara ett. Lika så kan ett problem ha flera möjliga förbättringsförslag för att lösa dem. Även förbättringar i from av nya instruktioner där hela aktiviteter är inkluderade har föreslagits.

Substantial benefits can be achieved through the adoption of lean type thinking earlier at the design stage to create more viable products. A complex design cannot be easily leaned out in production; therefore, the production of affordable and sustainable products requires effective lean design considerations at the conceptual level. The research presented in this thesis investigates and demonstrates the application of lean design for product enhancement. The aim of the research was to develop a novel lean design framework that would support the generation of product design with attributes such as maximise value, manufacturable, and operable with minimum waste and resources ensuring avoidable harm is eliminated. The framework consists of a systemised process which is organised in to phases and activities that provides a unique practical manner to lean out a design. The construction of the framework initiated with an extensive literature review and proceeded with an industrial field study which consisted of 34 interviews with 11 manufacturing companies in Europe. The findings were amalgamated to generate a lean design definition and principles which would form the foundations of the framework. A real-life industrial case study of an offshore oil/water separator was used to validate the framework. In conclusion, the lean design framework provides the necessary means by which a lean design can be achieved. As a result a functionally viable and enhanced design that is cheaper to manufacture through controlling waste and eliminating avoidable harm occurrence can be realised with minimal effort. The research makes the following contributions: (1) identification of essential elements in lean design, (2) generation of a lean design definition and principles, (3) Lean Design Framework development and (4) illustrative guidelines based on the framework to be used by designers in realising a lean product design.

ANNOTATION Václav Řídký Implementation of modern quality control metods in production of electromotors Diploma thesis, Institute of metrology and quality assurance testing, UT FME, Brno This diploma thesis deals with problems of reducing the complaints quota in production of electromotors to acceptable level. This work includes analysis of faults, presentation of single faults and instituted measures leading to the elimination their inception.

The objectives of Sensor Based Fixture Design and Verification (SFDV) research are to provide the means for detecting contact failure of the workpiece with fixture locators and for preventing incorrect loading of the workpiece in a fixture. The fixtures that involve complex free-form surfaces especially in the aerospace industries face problems caused by the contact failure of the workpiece with locators. In batch and mass production defects often occur due to incorrect loading of the workpiece in a fixture by an operator due to fatigue or inadvertence. The current fixturing research is focussed on improving the fixture quality and other aspects and do not address these issues. This research is focussed on three areas, to generate algorithms for automatically foolproofing the fixtures, to build locators with embedded sensors that could be used to verify the contact and foolproof the existing fixtures, and to design and experimentally validate fixtures for free-form surfaces with sensors to verify the location. In foolproofing, workpieces were classified into different categories to identify the existence of a solution and the geometry was simplified and used to search for a solution based on symmetry/asymmetry to discover a foolproofing location. The algorithms were implemented in a CAD software and the solutions were verified in 3D space. The locators with inbuilt sensors were designed for foolproofing and location verification purposes and the sensors were used in case studies to establish credibility. A sensor based fixture design method is created for the part location of free-form surfaces using fiber optic sensors. An experimental fixture with sensors incorporated in the locators was used to determine the effects of surface curvature on the sensitivity of the sensors. A new theory on best locations for the sensor based locators by utilizing surface curvature is proposed based on the experimental results. The SFDV implementation may help realize the dream for any manufacturing sys­tem aspiring to move beyond the six sigma levels of quality and achieve zero defects.

El presente trabajo de investigación tiene como objetivo mejorar la operatividad de alumbrado público en la empresa Luz del Sur S.A.A. Se identificaron las causas principales y para ello, se aplicó la metodología del Lean, cuyas herramientas y metodologías nos permitirá brindar una propuesta de solución sólida a la problemática actual antes mencionada. Primero se realizó la revisión bibliográfica, citando fuentes y artículos científicos que sustente y avalen la investigación. Luego, se realizó el análisis de la problemática actual y determinación de las causas, en donde se aplicaron métodos y herramientas de la ingeniería industrial para evidenciar la causa raíz del problema. A consecuencia de este análisis se formula la hipótesis para la aplicación del Lean con la ayuda de las herramientas Estandarización, VSM, Jidoka, Kaizen, Estudio de tiempos y Poka Yoke, quienes permitirán mitigar el impacto económico y operativo del problema principal los cuales son disminuir los sobre procesos y reducir las atenciones fuera de plazo en la operatividad del alumbrado público. Finalmente aplicando las mejoras descritas se puede ahorrar hasta en un 11.49% del presupuesto del área de OAP y estar dentro del estándar de trabajo según Osinergmin. / The present research work aims to improve the operation of public lighting in the company Luz Del Sur S.A.A. The main causes were identified and for this, the Lean methodology was applied, whose tools and methodologies will allow us to provide a solid solution proposal to the current problem mentioned above. First, the bibliographic review was carried out, citing sources and scientific articles that support and endorse the research. Then, the analysis of the current problem and determination of the causes was carried out, where industrial engineering methods and tools were applied to show the root cause of the problem. As a result of this analysis, the hypothesis for the application of Lean is formulated with the help of the tools like Standardization, VSM, Jidoka, Kaizen, Time Study and Poka Yoke, which will allow to mitigate the economic and operational impact of the main problem, which is to reduce processes and reduce late attentions in the operation of public lighting. Finally, applying the improvements described can save up to 11.49% of the budget of the OAP area and be within the work standard according to Osinergmin. / Trabajo de Suficiencia Profesional

El presente trabajo de investigación, tuvo como objetivo plantear una propuesta de mejora en el proceso de atención post venta en tiendas presenciales en Lima de una empresa de telecomunicaciones en el Perú, aplicando herramientas de Lean Service y estandarización de trabajo. La empresa en estudio, presenta un nivel de satisfacción del cliente de 67% en promedio anual, mientras que el objetivo planteado debe ser mayor a 72%, la casa matriz tiene un nivel de 80%. El bajo porcentaje de satisfacción de los clientes se debe principalmente a dos motivos: Tiempo elevados que representa un 33% e Información errónea con un 30%, de los motivos de baja satisfacción. Ello implica una pérdida económica para la empresa de S/ 9,112,519 de soles en el periodo febrero 2019 – enero 2020, este impacto representa el 1,7% del ingreso bruto anual, considerando solo telefonía móvil en Lima del periodo en estudio. Ante la problemática presentada, se propone la implementación de herramientas de Lean Service como: Estandarización de trabajo y Poka Yoke, lo cual permitió reducir el tiempo en los procesos de mayor impacto para la compañía: en renovación se redujo un 22%, en reposición un 18% y en suspensión un 17%. Finalmente se concluye que el proyecto es viable debido al análisis realizado mediante los indicadores económico, obteniendo un VAN de S/ 200,650 y una TIR de 61%, además el índice de rentabilidad (IR) del proyecto es de 4.4, esto indica que por cada sol invertido se obtiene una ganancia de 3.4. / The objective of this research work was to propose a proposal for improvement in the post-sale service process in face-to-face stores in Lima of a telecommunications company in Peru, applying Lean Service tools and work standardization. The company under study has a customer satisfaction level of 67% on an annual average, while the objective set must be greater than 72%, the parent company has a level of 80%. The low percentage of customer satisfaction is mainly due to two reasons: High time, which represents 33% and Erroneous information with 30%, of the reasons for low satisfaction. This implies an economic loss for the company of S / 9,112,519 soles in the period February 2019 - January 2020, this impact represents 1.7% of the annual gross income, considering only mobile telephony in Lima for the period under study. Given the problem presented, the implementation of Lean Service tools such as: Work standardization and Poka Yoke is proposed, which allowed reducing the time in the processes of greatest impact for the company: in renovation it was reduced by 22%, in replacement a 18% and 17% in suspension. Finally, it is concluded that the project is viable due to the analysis carried out through the economic indicators, obtaining a NAN of S / 200,650 and an TIR of 61%, in addition, the profitability index (IR) of the project is 4.4, and this indicates that for each Invested sol, a profit of 3.4 soles is obtained. / Trabajo de Suficiencia Profesional

Genom rapporten kommer kunskapen öka kring identifiering och reducering av flaskhalsar baserade på simuleringsverktyget Facts Analyzer och lean-verktyg. Den ökade kunskapen kommer generera möjligheter för företag att arbeta på ett strukturerat och effektivt vis genom en egenutvecklad arbetsmodell. Modellen kommer ge förutsättningar för företag att öka sin produktivitet och samtidigt reducera totala kostnaderna. Metoderna som arbetsmodellen bygger på är kvantitativ, kvalitativ, abduktion och förverkligas genom tillämpning på ett fallföretag där syftet är att undersöka applicerbarheten och ifall produktionen kan effektiviseras.  Med simuleringsverktyg skapas tydliga och fakta-baserade resultat på flaskhalsar och vad olika förbättringsalternativ har för påverkan på produktionen, därmed anses det vara ett bra verktyg att basera beslut på innan investeringar genomförs. Utifrån de identifierade flaskhalsarna, med hjälp av simuleringsverktyget, är det bevisat att lean-verktyg kan användas för att optimera produktion och reducera icke värdeskapande moment. Exempelvis visar resultatet att 5S, Kaizen, Poka Yoke, Total Productive Maintenance och Overall Equipment Efficiency är effektiva lean-verktyg.  För att öka produktionskapaciteten handlar det om att först identifiera flaskhalsarna genom simuleringsverktyget. Därefter beräknas flaskhalsens OEE-värde som skapar indikationer om begränsningarna och därmed belyser vart förbättringsförslag behövs. Genom indikationerna tillsammans med ytterligare lean-verktyg skapas därefter förbättringsförslag med fokus på att reducera flaskhalsen. För att däremot identifiera totalkostnadsreducering och icke värdeskapande aktiviteter används istället observationer och intervjuer med personalen. Därefter utvecklas förbättringsförslag, liksom för produktionskapaciteten, genom lean-verktyg för att minimera Muda. / Through the report, knowledge will increase regarding the identification and reduction ofbottlenecks based on the simulation tool Facts Analyzer and lean-tools. The increasedknowledge will generate opportunities for companies to work in a structured and efficientway through a own developed work model. The model will provide the conditions forcompanies to increase their productivity and at the same time reduce total costs. The methodson which the work model is based are quantitative, qualitative, abduction and are realized through a case company where the aim is to investigate the applicability and if productioncan be made more efficient. With simulation tools, clear and fact-based results are created on the effect differentimprovement options have on production, and thus it is considered a good tool to basedecisions on before investments are made. Based on the identified bottlenecks, with the helpof the simulation tool, it is proven that lean-tools can be used to optimize production andreduce non-value-creating activities. For example, the results show that 5S, Kaizen, PokaYoke, Total Productive Maintenance and Overall Equipment Efficiency are effectivelean-tools. To increase production capacity, it is a matter of first identifying the bottlenecks through thesimulation tool. The bottleneck's OEE value is then calculated, which creates indications ofthe limitations and thus highlights where improvement proposals are needed. Through theindications together with additional lean-tools, improvement proposals are then created with afocus on reducing the bottleneck. In contrast, to identify total cost reduction andnon-value-creating activities, observations and interviews with the staff are used instead.Improvement proposals are then developed, as for the production capacity, through lean-toolsto minimize Muda.