Comments and Discussions: Soemon TAKAKUWA (高桑 宗右ヱ門)

When the profit is compressed by the cost, quality, delivery, efficiency and flexibility in the tranditional industries, it is always the focus for the academic community and the field about how to build up two basic forces of competition: ¡§quick response¡¨ and ¡§competitive advantage¡¨ in the trends toward continuously short life cycle of product and extremely small amount yet many varieties of product. Applying lean production with ¡§small quantity yet most variety¡¨ to the activities of business operation is expected to create a highly lean and refined enterprise through the process of management in the company operation and to make more benefits to reach the goal of business and survive in the field. This research discusses if ¡§customer participatation¡¨, ¡§the relations with suppliers¡¨ and ¡§the management technique of organization¡¨ quoted from the the management concepts of lean production influence manufacturing efficiency and also treats the correlation between them. Furthermore, it verifies the difference between each dimension of management concept of lean production mentioned above with the organization performance. It takes the tranditional manufacturing industry in Taiwan as the objects of sampling and collects the cognitions of the interviewed on the three measuring dimensions including relation with suppliers, the management technique of organization, and customer participatation to the agreement degree for the execution inside organization and also the agreement degree to suppliers. The raw data are verified by SPSS software package and we get some conclusions below: There is remarkable positive influence between the suppliers with lean production and manufacturing performance. The factor of suppliers¡¦ participation has direct influence, and the next is information feedback from suppliers. But no direct influence existed to those suppliers with JIT delivery. There is remarkable positive influence between the management technique of organization and manufacturing performance. We find direct positive effect between manufacturing process SPC and employees¡¦ participation EMP. But there is no remarkably direct influence to ¡§Pull production¡¨, ¡§Continuous production process¡¨, ¡§ Shorten preparing time¡¨ and ¡§Total production maintenance¡¨. However, the influences of ¡§ Shorten preparing time¡¨, ¡§Total production maintenance¡¨ are bigger than ¡§Pull production¡¨ and ¡§Continuous production process¡¨. There is remarkable positive influence between the customers with lean production and manufacturing performance. Mainly direct influence effect for customer participation exists but no direct influence effect for information feedback from suppliers relatively. There is remarkable positive influence between the suppliers with lean production and customers¡¦ participation. The study finds that there is direct influence effect for information feedback from suppliers and customers¡¦ participation. Second are suppliers¡¦ participation and suppliers with JIT delivery. The result of this research provides managers in the manufacturing industry a path to improve the manufacturing performance of company by undertaking 5 remarkable indexes: (1) Suppliers¡¦ participation, (2) Information feedback from suppliers, (3) Management of manufacturing process, (4) Employees participation, (5) Customers¡¦ participation. Enhancing the relations with suppliers as well as customer participation, and upgrading management technique of organization will effectively improve the quality and delivery performance for the suppliers. Also it improves the manufacturing performance, and promotes the satisfication level of customers to increase enterprise¡¦s competition at last.

<p>ITT Flygt är ett internationellt bolag som producerar mixers och dränkbara pumpar för den globala marknaden. Den största produktionsanläggningen är placerad i Sverige men det finns ett flertal fabriker runt om i världen, till exempel i Kina. Den kinesiska fabriken i Shenyang producerar pumpar som tillhör det lilla och mellanstora sortimentet. För att vinna fördelar på den kinesiska marknaden har ett projekt startas med målet att komplettera den befintliga tillverkningen i Kina med tillverkning av de största pumparna. Denna rapport beskriver en förstudie av ett produktionssystem anpassat för tillverkning av stora pumpar i Kina.</p><p>En studie av det befintliga produktionssystemet för stora pumpar i Sverige ger en möjlighet att dela in tillverkningen i olika mindre delar, processer. Innehållet i varje process, gränssnitten mellan dem och de resurser som behövs för varje process kartläggs. Dessa parametrar tillsammans med en lista över befintliga resurser i Kina utgör grunden för att ta fram alternativ för det nya produktionssystemet i Kina. De befintliga resurserna i Kina kartläggs med hjälp av intervjuer och studiebesök till fabriken i Shenyang. Det finns ytterligare en fabrik i Kina som kan användas för tillverkningen av stora pumpar. Den är belägen i Nanjing och erbjuder en möjlighet att prova pumpar med befintlig utrustning.</p><p>Bland de möjliga alternativen för ett nytt produktionssystem finns en lösning där alla processer görs i Shenyang men även flera alternativ där tillverkningen delas mellan de två fabrikerna för att utnyttja befintliga resurser så effektivt som möjligt. I jämförelsen mellan de olika alternativen belyses de möjliga lösningarnas fördelar och nackdelar för att ge en så god jämförelse mellan alternativen som möjligt.</p><p>Rekommendationerna är baserade på praktiska aspekter och de teorier som presenteras i rapportens teoridel. Stor vikt har lagts vid förmågan att utnyttja befintliga resurser för att minimera investeringsbehovet och därigenom kompensera för de låga produktionsvolymer som blir aktuella för tillverkningen av stora pumpar i Kina. Det rekommenderade förslaget utnyttjar båda fabrikerna i Kina. Bearbetning och huvudmontering kan göras i Shenyang medan provning och de processer som kommer efter provningen bör göras i Nanjing. Målningens placering bör utredas ytterligare genom att jämföra kostnaderna för de investeringar som måste göras i de olika fabrikerna och väga dem mot fördelarna med att måla pumparna i Shenyang.</p><p>Den rekommenderade lösningen beskrivs på en övergripande nivå där fokus lagts på ordningen i vilken de olika processerna utförs samt var processerna placeras. Nästa steg för företaget är att gå igenom förslaget på en mer detaljrik nivå och designa produktionssystemet mer i detalj för att förbereda för produktionen av stora pumpar i Kina.</p> / <p>ITT Flygt is an international company that produces mixers and submersible pumps for a global market. The main production site is located in Sweden but there are other production plants all over the world, for instance in China. The plant in Shenyang, China, manufactures small and midsize pumps but in order to gain advantages on the Chinese market a project to start production of the largest pumps in China has been initiated. This thesis describes a study of possible alternatives for a production system dedicated to the production of large pumps in China.</p><p>A study of the existing production system for large pumps in Sweden gives a chance to divide the production into smaller parts, processes, to facilitate the future work. The content of each process, the interfaces between the processes and the resources needed for each process are examined. These parameters and the list of existing resources in China are used in the process of generating alternatives for the new production system in China. The list of existing resources in China is created by the means of interviews and studies of Flygt’s factory in Shenyang. There is also another factory in China that can be used for the new production system. This plant, located in Nanjing, can also be used for testing pumps and for other processes, but it has not been visited.</p><p>The possible alternatives include a solution where all the processes are performed in Shenyang and several different options where the work is divided among the two plants in order to utilize the existing resources in the best possible way. In the discussion of possible alternatives their strengths and weaknesses are discussed so that all the proposed ideas are compared relative to each other.</p><p>The recommendations are based on practical aspects as well as theories presented in the theoretical framework. Much emphasis is given to the ability to use existing knowledge and resources in order to minimize the need for investments to compensate for the low volume of large pumps that initially will be produced in China. The recommended system is a solution where both plants are used. The machining and main assembly should be located in Shenyang and the testing and all the processes following the testing should be located in Nanjing. The location of the washing and painting process has to be analyzed further by comparing the costs for needed investments. The costs should also be compared to the advantages of locating the washing and painting process in Shenyang.</p><p>The recommended solutions are discussed on a comprehensive level, mainly focusing on the location and the order of the processes. The next step for the company is to design the processes in detail in order to prepare for the production of large pumps in China.</p>

The process of multi-objective optimization involves finding optimal solutions to several objective functions. However, these are typically in conflict with each other in many real-world problems, such as production system design. Advanced post-optimization analysis can be used to provide the decision maker with information about the underlying system. The analysis can be based on the combination of simulation-based multi-objective optimization and learning from the obtained solution set. The goal of the analysis is to gain a deeper understanding of the problem at hand, to systematically explore and evaluate different alternatives, and to generate essential information and knowledge to support the decision maker to make more informed decisions in order to optimize the performance of the production system as a whole. The aim of this work is to explore the possibilities on how post-optimization analysis can be used in order to provide the decision maker with essential information about an underlying system and in what way this information can be presented. The analysis is mainly done on production system development problems, but may also be transferred to other application areas. The research process of the thesis has been iterative, and the initial approach for post-optimization analysis has been refined several times. The distance-based approach developed in the thesis is used to allow the extraction of information about the characteristics close to a user-defined reference point. The extracted rules are presented to the decision maker both visually, by mapping the rules to the objective space, and textually. The method has been applied to several industrial cases for proof-by-demonstration as well as to an artificial case with information known beforehand to verify the distance-based approach, and the extracted rules have also been used to limit the search space in the optimization. The major finding in the thesis is that to learn from optimization solution sets of production system problems with stochastic behavior, a distance-based approach is advantageous compared with a binary classification of optimal vs. non-optimal solutions. / <p>At the time of the doctoral defence the following articles were unpublished and had a status as follows: Paper 5: Epubl ahead of print; Paper 6: Accepted.</p>

ITT Flygt är ett internationellt bolag som producerar mixers och dränkbara pumpar för den globala marknaden. Den största produktionsanläggningen är placerad i Sverige men det finns ett flertal fabriker runt om i världen, till exempel i Kina. Den kinesiska fabriken i Shenyang producerar pumpar som tillhör det lilla och mellanstora sortimentet. För att vinna fördelar på den kinesiska marknaden har ett projekt startas med målet att komplettera den befintliga tillverkningen i Kina med tillverkning av de största pumparna. Denna rapport beskriver en förstudie av ett produktionssystem anpassat för tillverkning av stora pumpar i Kina. En studie av det befintliga produktionssystemet för stora pumpar i Sverige ger en möjlighet att dela in tillverkningen i olika mindre delar, processer. Innehållet i varje process, gränssnitten mellan dem och de resurser som behövs för varje process kartläggs. Dessa parametrar tillsammans med en lista över befintliga resurser i Kina utgör grunden för att ta fram alternativ för det nya produktionssystemet i Kina. De befintliga resurserna i Kina kartläggs med hjälp av intervjuer och studiebesök till fabriken i Shenyang. Det finns ytterligare en fabrik i Kina som kan användas för tillverkningen av stora pumpar. Den är belägen i Nanjing och erbjuder en möjlighet att prova pumpar med befintlig utrustning. Bland de möjliga alternativen för ett nytt produktionssystem finns en lösning där alla processer görs i Shenyang men även flera alternativ där tillverkningen delas mellan de två fabrikerna för att utnyttja befintliga resurser så effektivt som möjligt. I jämförelsen mellan de olika alternativen belyses de möjliga lösningarnas fördelar och nackdelar för att ge en så god jämförelse mellan alternativen som möjligt. Rekommendationerna är baserade på praktiska aspekter och de teorier som presenteras i rapportens teoridel. Stor vikt har lagts vid förmågan att utnyttja befintliga resurser för att minimera investeringsbehovet och därigenom kompensera för de låga produktionsvolymer som blir aktuella för tillverkningen av stora pumpar i Kina. Det rekommenderade förslaget utnyttjar båda fabrikerna i Kina. Bearbetning och huvudmontering kan göras i Shenyang medan provning och de processer som kommer efter provningen bör göras i Nanjing. Målningens placering bör utredas ytterligare genom att jämföra kostnaderna för de investeringar som måste göras i de olika fabrikerna och väga dem mot fördelarna med att måla pumparna i Shenyang. Den rekommenderade lösningen beskrivs på en övergripande nivå där fokus lagts på ordningen i vilken de olika processerna utförs samt var processerna placeras. Nästa steg för företaget är att gå igenom förslaget på en mer detaljrik nivå och designa produktionssystemet mer i detalj för att förbereda för produktionen av stora pumpar i Kina. / ITT Flygt is an international company that produces mixers and submersible pumps for a global market. The main production site is located in Sweden but there are other production plants all over the world, for instance in China. The plant in Shenyang, China, manufactures small and midsize pumps but in order to gain advantages on the Chinese market a project to start production of the largest pumps in China has been initiated. This thesis describes a study of possible alternatives for a production system dedicated to the production of large pumps in China. A study of the existing production system for large pumps in Sweden gives a chance to divide the production into smaller parts, processes, to facilitate the future work. The content of each process, the interfaces between the processes and the resources needed for each process are examined. These parameters and the list of existing resources in China are used in the process of generating alternatives for the new production system in China. The list of existing resources in China is created by the means of interviews and studies of Flygt’s factory in Shenyang. There is also another factory in China that can be used for the new production system. This plant, located in Nanjing, can also be used for testing pumps and for other processes, but it has not been visited. The possible alternatives include a solution where all the processes are performed in Shenyang and several different options where the work is divided among the two plants in order to utilize the existing resources in the best possible way. In the discussion of possible alternatives their strengths and weaknesses are discussed so that all the proposed ideas are compared relative to each other. The recommendations are based on practical aspects as well as theories presented in the theoretical framework. Much emphasis is given to the ability to use existing knowledge and resources in order to minimize the need for investments to compensate for the low volume of large pumps that initially will be produced in China. The recommended system is a solution where both plants are used. The machining and main assembly should be located in Shenyang and the testing and all the processes following the testing should be located in Nanjing. The location of the washing and painting process has to be analyzed further by comparing the costs for needed investments. The costs should also be compared to the advantages of locating the washing and painting process in Shenyang. The recommended solutions are discussed on a comprehensive level, mainly focusing on the location and the order of the processes. The next step for the company is to design the processes in detail in order to prepare for the production of large pumps in China.

Manufacturing Industry as an important part of European and Swedish economy faces new challenges with the daily growing global competition. An enabler of overcoming these challenges is a rapid transforming to a value-based focus. Investment in innovation tools for production system development is a crucial part of that focus which helps the companies to rapidly adapt their production systems to new changes. Those changes can be categorized to incremental and radical ones. In this research we studied the Obeya concept as a supporting tool for production system development with both of those approaches. It came from Toyota production system and is a big meeting space which facilitates communication and data visualization for a project team. Four lean companies have been studied to find the role of such spaces in production development. Results indicate a great opportunity for improving those spaces and their application to radical changes in production development projects / EXPRES

This Master‘s thesis describes throughput of manufacturing order in company Walter s.r.o. It is a proposal of improvement system to monitoring order in mounting. Better told, it is unification of dates to central place and accessing to all concern. This company belongs to the group WALTER MASCHINENBAU GmbH. The bussines comunity deals with developments, production and selling of CNC (by computer numeric controlled) machines for production, fine grinding and measuring tools.

El problema principal que se desarrolla en la tesis es la existencia de un alto volumen de pan que no se llega a vender, seguido del atraso en la entrega de insumos y la presencia alta de mermas en el proceso de producción. Las micro y pequeñas empresas aportan aproximadamente el 24% al PBI nacional y dan empleo al 75% de la PEA. Las Mypes que se dedican a la elaboración de panes, durante el primer trimestre del año 2018 tuvo un crecimiento del 4.1% con respecto al año anterior. Tomando en cuenta la importancia del sector, es importante fortalecer su desempeño en un mercado muy competitivo. En ese sentido, se llevó a cabo una revisión literaria con el fin de dar solución al problema encontrado. Existen investigaciones donde se implementa la estandarización del trabajo, modelado de procesos y planificación de producción. Sin embargo, todos los casos de estudio de esas investigaciones son empresas con un buen nivel de madures o difieren mucho de la realidad de las microempresas peruanas. Por todo lo dicho anteriormente, en la presente tesis se propone un sistema básico de gestión que ayuda a reducir los tres principales problemas expuestos. Este sistema lo componen tres procesos, gestión de calidad, planificación y control de la producción y gestión logística. Así mismo, cada proceso tiene herramientas como el modelado de proceso, Sipoc, indicadores y formatos. La implementación del sistema se llevó en la panadería Cosmos y se obtuvo un aumento de la productividad de 89.90% a 94.81%. / The main problem that develops in the thesis is the existence of a high volume of bread that does not reach a seller, followed by the delay in the delivery of supplies and the high presence of losses in the production process. Micro and small companies contribute approximately 24% to the national PIB and employ 75% of the EAP. The Mypes that are dedicated to the production of panels, during the first quarter of 2018 had a growth of 4.1% compared to the previous year. Taking into account the importance of the sector, it is important to strengthen its performance in a very competitive market. In this sense, a literary review was carried out in order to solve the problem found. There are researches where work standardization, process modeling and production planning are implemented. However, all the case studies of these investigations are companies with a good level of studies or differ greatly from the reality of Peruvian micro-companies. For all the aforementioned, in this thesis a basic management system is proposed that helps to reduce the three main problems affected. This system is made up of three processes, quality management, production planning and control, and logistics management. Likewise, each process has tools such as process modeling, Sipoc, indicators and formats. The implementation of the system was carried out in the Cosmos bakery and an increase in productivity was obtained from 89.90% to 94.81%. / Trabajo de suficiencia profesional

No description available.

In many situations, different consumers have different degrees of willingness to wait to get delivery of a product. So, consumers can be segregated based upon the demand lead time they are providing. In this paper, two types of consumers have been considered. The first category needs immediate delivery of the product, so there is no demand lead time; whereas for the other category, demand lead time is positive. A manufacturer, which produces the items using a base stock policy, can benefit from the advance demand information that the second category of consumers are providing. Early fulfillment for a particular order means fulfilling the order before the demand lead time. In this research, it is shown that a restrictive early fulfillment policy can help the firm to reduce the chances of order loss. A production control approach for restrictive early fulfillment is discussed and the factors that may affect the early fulfillment policy are examined. / Master of Science