The Republic of South Africa’s energy economy is under immense pressure and the main energy utility, Eskom, cannot reliably generate sufficient electrical energy to meet its customer demand. Water security in South Africa is also under threat as the country is currently amidst a water crisis. The South African manufacturing industry is the sector consuming the largest portion of the total energy consumption and second largest portion of the total water consumption (excluding urban use) nationally. Water and energy efficiency improvement is becoming imperative for organisational success as well as national economic sustainability. This is due to the significant increase in the cost of both electrical energy and water in recent years, and the drop in the reserve energy margin below the minimum level required for sustainable operation of energy utilities. The research objective therefore was to develop a Lean-based water and energy efficiency improvement framework for the manufacturing industry to encourage and realise a reduced demand for energy and water in it. A literature review was conducted on the water and energy landscape in South Africa, Lean manufacturing principles and their positive natural influence on water and energy efficiency, and the Value Stream Mapping tool. The survey of water and energy wastes in the manufacturing industry yielded the creation of standardised water and energy waste categories for use in conjunction with the conventional Lean wastes, tools and techniques. The literature survey indicated that the implementation of Lean manufacturing techniques naturally leads to the improvement of energy and water intensity. The researcher hypothesised that there is even greater potential for water and energy savings if a Lean-based tool is developed to specifically focus on the improvement of energy and water efficiency. A framework for this tool was developed through the literature survey. The tool is based on the Value Stream Mapping tool. A practical experiment was then conducted to establish the effectiveness of the tool in the South African manufacturing industry. The experiment design included an outline of the forecasting and statistical validation techniques to ensure the integrity of data utilised for approving or disproving the set hypotheses. The results of the practical experiment yielded positive results, confirming the hypothesis that the implementation of the developed framework will lead to improved energy and water efficiency in the manufacturing industry. After an explanation of the experimental results, the study concluded with recommendations and conclusions based on the findings.

The aim is to use Lean Administration metodology to improve custom clearance process steps that do not add value, but it is necessary to carry out them due to legislative reasons. The company has excellent results of applying the Lean principles in manufacturing and this thesis will bring to the company specific application of Lean Enterprise metodolgy outside manufacturing. The thesis is proof of the implementation of the company philosophy of continuous improvement, perfection does not exist, there is always the possibility of improvement.

Orientador: Flavio Augusto Picchi / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Civil, Arquitetura e Urbanismo / Made available in DSpace on 2018-08-22T04:53:50Z (GMT). No. of bitstreams: 1 Lacerda_SergiodaSilva_M.pdf: 1255042 bytes, checksum: f36772f7e92811df442a6c0235d462c9 (MD5) Previous issue date: 2013 / Resumo: O resumo poderá ser visualizado no texto completo da tese digital / Abstract: The abstract is available with the full electronic document / Mestrado / Arquitetura e Construção / Mestre em Engenharia Civil

Submitted by Nadir Basilio (nadirsb@uninove.br) on 2017-08-04T21:13:57Z No. of bitstreams: 1 Wanderley Sussai dos Santos.pdf: 5337961 bytes, checksum: e649b009252785c5448fb3301e737a88 (MD5) / Made available in DSpace on 2017-08-04T21:13:57Z (GMT). No. of bitstreams: 1 Wanderley Sussai dos Santos.pdf: 5337961 bytes, checksum: e649b009252785c5448fb3301e737a88 (MD5) Previous issue date: 2017-02-24 / The industrial plant floor is increasingly pressured by stakeholders (society, customers, government, etc.) to adopt a sustainable philosophy to achieve the reduction of environmental, social and economic impact in manufacturing processes; and it is the manufacturing phase that contributes most to the environmental impact. Therefore, the purpose of this paper is to analyze, through a case study, the applicability of lean manufacturing, mainly the practical value stream mapping of the flow of value to measure sustainability, that is, to measure environmental losses, social losses and economic losses from the manufacturing process of a specific product (in this case a water-cooled cable manufacturing process). As a result of the research, it was possible to identify and quantify the economic, environmental and social losses at each stage of the manufacturing process, such as lead time, excess and loss of water, energy and raw materials, and potential risks health and safety of employees. / O chão-de-fábrica industrial é cada vez mais pressionado pelas partes interessadas (sociedade, clientes, governo, etc.) para a adoção da filosofia sustentável para a obtenção da redução do impacto ambiental, social e econômico nos processos de fabricação; e é a fase de fabricação que mais contribui, principalmente, para o impacto ambiental. Portanto, este trabalho tem como proposta analisar, através de um estudo de caso, a aplicabilidade da manufatura enxuta, principalmente da prática de mapeamento de fluxo de valor para medir a sustentabilidade, ou seja, medir as perdas ambientais, as perdas sociais e as perdas econômicas do processo de fabricação de um produto específico (no caso, um processo de fabricação de cabos refrigerados a água). Como resultado de pesquisa, foi possível identificar e quantificar as perdas econômicas, ambientais e sociais em cada etapa do processo de fabricação, como, por exemplo, o lead time, excesso e perda de água, de energia e de matéria-prima, e os riscos potenciais à saúde e segurança dos colaboradores.

The diploma thesis is concerned with the implementation of lean components in the production process of selected company. Through the Value Stream Mapping method an analysis of the current state is performed that resulted several shortcomings of the current production process. Based on the outcomes of the analysis, proposal of new production line is made that contributes to increased customer value within a shorter production time, reduce waste and thus to streamlining the production process.

The diploma thesis is focused on the implementation of lean production con-ditions into the production process of the selected company, analyze and find bottleneck. Aim of thesis is to eliminate the downtime of the production pro-cess to provide lean conditions for the selected section when introducing a new product and new facilities at the worplace. First part of thesis is devoted to literature review and dealingwith teheoteri-calpreparation, understanding principles and methods of lean production. Second part is dealing with analyzing production processes of product and in-dividual production operations, application of lean production methods and proposals for a new organization of the workplace.

I dagens samhälle överutnyttjas jordens resurser. Dagens levnadssätt och klimatförändringarna som sker, leder därför till att högre krav ställs på företag att arbeta med hållbarhetsfrågor och sträva efter resurseffektiva arbetsmetoder. För att företag ska bli mer resurseffektiva kan det krävas verktyg eller arbetsmetoder som hjälper till att identifiera områden med förbättringspotential. I den här studien analyserades Leanverktyget värdeflödesanalys och dess tillämpbarhet på processindustrin. Värdeflödesanalys är ett kartläggningsverktyg som används för att identifiera förluster och flödesbegränsade faktorer relaterade till en tillverkningsprocess. Kartläggningen analyserar såväl information- som materialflöde. Författarna vill med den här studien undersöka hur värdeflödesanalys kan tillämpas eller anpassas till en kontinuerligt tillverkande miljö. Studien är gjord som en fallstudie hos Stora Enso Skoghall där datainsamlingen har gjorts genom en kartläggning av flödet, en enkätundersökning och semistrukturerade intervjuer. Studien visar att verktyget kan tillämpas på processindustrin då det ger en bra översikt över processerna och indikerar områden som kan ses som flödesbegränsande. Som verktyg för förlustidentifiering krävs det att kartläggningen kompletteras med ytterligare analysmetoder för att få en tydligare bild över vilka förluster som sker inom pappers- och massaindustrin. Värdeflödesanalysen kan bland annat utvecklas gällande en tydligare kartläggning av informationsflödet. Studiens författare anser också att kartläggningen av materialflödet kan utvecklas med mer information om hur avvikelser sker längs tillverkningen. Materialflödet kan också illustreras med hjälp av ett simulerande verktyg för att ge en mer korrekt bild över avvikelserna som sker. / In today's society, the earth's resources are overused. Today's way of living and the climate changes that are taking place therefore lead to higher requirements on companies to work with issues regarding sustainability and strive for resource-efficient working methods. For companies to become more resource efficient, tools may be needed to help and identify areas with potential for improvement. In this study, the Lean tool value stream mapping and its applicability to the process industry were analyzed. Value stream mapping is a mapping tool used to identify losses and flow-limiting factors related to a manufacturing process. The mapping analyzes both information and material flow. With this study, the authors want to investigate how value flow analysis can be applied or adapted to a continuous manufacturing environment. The study was conducted as a case study at Stora Enso Skoghall, where data collection was done through a mapping of the process, a questionnaire and semi-structured interviews. The study shows that the tool can be applied to the process industry as it provides a good overview of the processes and indicates areas that can be seen as flow-limiting. As a tool for loss identification, it is required that the mapping is supplemented with additional analysis methods in order to get a clearer picture of the losses that occur in the paper and pulp industry. The value stream mapping can, among other things, be developed regarding a clearer mapping of the information flow. The authors of the study also believe that the mapping of the material flow can be developed with more information about how deviations occur along the production. The material flow can also be illustrated with the help of a simulating tool to give a more correct picture of the deviations that occur.

This master's thesis is dealing value stream optimisation of finished goods in company Continental Automotive Systems, s. r. o. between production lines and expedition in terms of lean production methods and industrial engineering. The first part deals with theoretical training methodologies and understanding of lean manufacturing and industrial engineering. The second part analyzes the value stream of finished goods between production lines and expeditinon, identifying bottlenecks and design improvements.

The thesis is focused on the implementation of a lean component in the manufacturing process of First Brno Machinery Velká Bíteš, Ltd. With the help of lean componant Value Stream Mapping (VSM – value stream mapping) an analysis of the current status is determined that underlies the bottleneck analysis in the manufacturing process. Based on that analysis the optimal future state of the manufacturing process is designed which leads to a production efficiency. This thesis focuses on increasing customer value and reducing waste in manufacturing.

This master’s thesis concerns optimization of quotation process. It describes mapping of value stream by VSM Method (value stream mapping) in practical way in order to minimize cost. Further on it describes three points of view method when surveying and modifying process. It analyses process on three levels and describes suitable solution which makes process smoother and more effective. At the conclusion of this diploma project belongs evaluation of realised solutions and measures that need to be taken in future.