<p>In this thesis was a model developed, in order to improve deficiencies in existing literature regarding the layout problem and to give companies a comprehensible user-friendly procedure on how to design competitive production processes, plant layouts and material handling systems. The model consists of six phases that can be used sequentially in order to design, evaluate, implement and maintain effective plant layouts and material handling systems. The model can also be used to examine and optimize processes. The first four phases of the model were tested successfully in a case study at Holtab AB, a medium sized manufacturing company in Tingsryd.</p>

El presente trabajo de investigación tiene como objetivo reducir el índice de devoluciones de una empresa de consumo masivo. Se aplicó la metodología Lean Warehousing y la herramienta VRP para plantear una solución al problema. El proyecto se divide en cuatro capítulos. En el primer capítulo se desarrolla los conceptos y bases teóricas en las que se fundamenta la propuesta. El segundo capítulo presenta el entorno de la empresa, los procesos realizados y los roles que desempeñan cada uno de los trabajadores. También, se identifica el problema a resolver, para ello se requirió utilizar como herramienta el árbol de decisiones para identificar las causas raíz, las cuales son explicadas y fundamentadas. El tercer capítulo plantea 2 metodologías que ayudarán a resolver las 4 causas principales. La primera metodología consiste en determinar la ruta de transporte óptima y la segunda metodología plantea mejorar el abastecimiento y control de productos dentro del almacén. Finalmente, se presenta los costos de la implementación y los beneficios que se obtendrían con la implementación de las propuestas. Por último, el cuarto capítulo se expone los resultados de la implementación con la finalidad de reducir el índice de devoluciones. Así como, la reflexión del proyecto y las recomendaciones para futuras investigaciones. / This research work aims to reduce the rate of returns of a mass consumption company. The Lean Warehousing methodology and the VRP tool were applied to propose a solution to the problem. The project is divided into four chapters. In the first chapter the theoretical concepts and bases on which the proposal is based are developed. The second chapter presents the company's environment, the processes performed and the roles that each of the workers play. Also, the problem to be solved is identified, for this it was required to use the decision tree as a tool to identify the root causes, which are explained and substantiated. The third chapter presents 2 methods to help resolve the 4 main causes. The first methodology consists in determining the optimal transport route and the second methodology proposes to improve the supply and control of products within the warehouse. Finally, the implementation costs and the benefits that would be obtained with the implementation of the proposals are presented. Finally, the fourth chapter describes the results of the implementation in order to reduce the rate of returns. As well as, the reflection of the project and the recommendations for future research. / Trabajo de Suficiencia Profesional

Den här kandidatuppsatsen har genomförts på Speed Group, ett företag inom logistik och produktion. Uppsatsen har som utgångspunkt att studera och effektivisera produktionsytor för att förbättra produktiviteten och resurseffektiviteten. Av resultaten ska författarna komma med förslag på förbättringar för att möta framtida marknadsbehov. Metoden för studien har varit en kombination av litteraturstudier, kvalitativa och kvantitativa forskningsmetoder samt empiriska studier genom planeringsmöten och datainsamling. FSLP har tillämpats för att analysera och förbättra produktionsflödet. Den totala observerade tiden inkluderade en omfattande analys av befintliga produktionslayouter, där ineffektiva områden identifierades och effektiviserade lösningar föreslogs. En stor del av studien fokuserade på att eliminera slöseri och förbättra materialhanteringen. Resultaten visade att betydande förbättringar i yteffektivitet och materialhantering kunde uppnås genom implementering av de nya layout samt framtida tillämpningar av Lean-strategier. Efter att ha identifierat och eliminerat flaskhalsar och ineffektivitet, samt effektiviserat produktionslayouterna, kan Speed Group förvänta sig ökad produktivitet och effektivitet. Slutsatsen av examensarbetet är att det finns många förbättringsområden att arbeta med. Det område som erbjuder den mest tydliga förbättringspotentialen är effektiviseringen av produktionslayout och materialhanteringen, vilket kräver kontinuerlig tillämpning av Lean-principerför att förhindra flaskhalsar i produktionsflödet. / This bachelor's thesis has been conducted at Speed Group, a company engaged in logistics and production. The thesis aims to study and optimize production areas to enhance productivity and resource efficiency. Based on the findings, the authors will propose improvements to meet future market demands. The methodology for the study combined literature reviews, qualitative and quantitative research methods, and empirical studies through planning meetings and data collection. FSLP was applied to analyze and improve the production flow. The total observed time included a comprehensive analysis of existing production layouts, where inefficient areas were identified and optimized solutions were proposed. A significant portion of the study focused on eliminating waste and improving material handling. The results showed that significant improvements in space efficiency and material handling could be achieved through the implementation of the new layouts and future applications of Lean strategies. By identifying and eliminating bottlenecks and inefficiencies, as well as optimizing the production layouts, Speed Group can expect increased productivity and efficiency. The conclusion of the thesis is that there are many areas for improvement to work on. The area offering the most obvious improvement potential is the optimization of production layout and material handling, which requires the continuous application of Lean principles to prevent bottlenecks in the production flow.

Submitted by JOSIANE SANTOS DE OLIVEIRA (josianeso) on 2019-03-13T12:19:46Z No. of bitstreams: 1 Lucas Schmidt Goecks_.pdf: 2315393 bytes, checksum: 3985e874dfb67958cda4aa69697f671f (MD5) / Made available in DSpace on 2019-03-13T12:19:46Z (GMT). No. of bitstreams: 1 Lucas Schmidt Goecks_.pdf: 2315393 bytes, checksum: 3985e874dfb67958cda4aa69697f671f (MD5) Previous issue date: 2018-12-30 / CAPES - Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / Como uma das atividades mais importantes na engenharia de produção, o planejamento de instalações consiste na tomada de decisões relativas ao leiaute dos setores, unidades de produção/ fabricação, locais de armazenamento, e assim por diante. Conceito que é apoiado pela variabilidade dos processos produtivos, que muda de um período de produção para outro e de uma empresa para a outra. Atualmente, a literatura apresenta abordagens de como solucionar o problema de leiaute para empresas de pequeno e médio porte com modelos de planejamento, e de tomada de decisão multicritérios, ou meta-heurísticos. A literatura aborda estes dois métodos de forma separada. Inclusive, não existem relatos de comparações entre eles desde o conhecimento do autor. Como resposta à esta lacuna de pesquisa, definiu-se o seguinte objetivo: "identificar um método para planejamento de leiautes aplicável em empresas de pequeno e médio porte". A meta foi desenvolver uma ferramenta de modelagem genérica e que atenda à diferentes necessidades. Sendo assim, este trabalho abordou o Systematic Layout Planning (SLP) e o Particle Swarm Optimization (PSO) para planejamento de leiautes, avaliando a melhor proposta pelo Analytic Hierarchy Process (AHP). Em decorrência de interesses práticos que visam à aplicação de ferramentas para a solução de problemas específicos, este trabalho classifica-se como pesquisa aplicada de abordagem quantitativa, embasado por processos de tomada de decisão e de modelagem. Os resultados obtidos demonstram que o SLP fornece melhores propostas de leiautes que o PSO, para pequenas e médias empresas. O SLP respeita a alocação adjacente dos setores de acordo com o fluxo de material, enquanto que o PSO distribui aleatoriamente as áreas produtivas, o que proporciona maior variabilidade nas propostas de leiautes. O SLP demandou maior tempo de planejamento e um método auxiliar (AHP) para definição da melhor proposta de leiaute. Já o PSO forneceu o melhor leiaute sem uma ferramenta de suporte e a simulação foi mais rápida após estruturação do modelo do algoritmo. Implicações práticas à esta pesquisa encontram-se na análise da redução de custos com dados reais. Foram identificados na literatura objetivos de otimização e restrições mais usuais. Quanto ao tipo de leiaute, conforme as características da empresa a ser explorada, será considerado o tipo job-shop/funcional. Esta pesquisa contribui ao meio acadêmico no âmbito de sintetizar dois métodos, distintos, para planejamento de leiautes e compará-los com uma ferramenta de tomada de decisão multicriterial. Ao meio empresarial, a mesma fornece métodos que podem ser incorporados ao cotidiano das empresas no que diz respeito ao planejamento de leiautes e tomada de decisões. / As one of the most important activities in production engineering, facility planning consists of making decisions regarding the layout of the sectors, production/manufacturing units, storage locations, and so on. This concept is supported by the variability of production processes, which changes from one period of production to another and from one company to another. Currently, the literature presents approaches of how to solve the problem of layout for small and medium-sized companies with models of planning, and decision-making multi-criteria, or metaheuristics. The literature addresses these two methods separately. In fact, there are no reports of comparisons between them since the knowledge of the author. In response to this research gap, the following objective was defined: "to identify a method for layout planning applicable to small and medium-sized enterprises". The objective was to develop a generic modeling tool that meets different needs. Thus, this work approached Systematic Layout Planning (SLP) and Particle Swarm Optimization (PSO) for the layout planning, evaluating the best proposal by the Analytic Hierarchy Process (AHP). Because of practical interests that aim at the application of tools for the solution of specific problems, this work is classified as applied research of quantitative approach, based on processes of decision-making and modeling. The results obtained demonstrate that SLP provides better layout proposals than the PSO, for small and medium enterprises. The SLP respects the adjacent allocation of the sectors according to the material flow, while the PSO randomly distributes the productive areas, which provides greater variability in the layout proposals. The SLP required greater planning time and an auxiliary method (AHP) to define the best layout proposal. The PSO provided the best layout without a support tool and the simulation was faster after structuring the algorithm model. Practical implications of this research lie in the analysis of cost reduction with real data. Optimization objectives and constraints that are more usual have been identified in the literature. As for the type of layout, according to the characteristics of the company, and because it is a single case study, the job-shop type will be considered. This research contributes to the academic environment in the context of synthesizing two distinct methods for planning layouts and comparing them with a multi-criteria decision-making tool. In the business environment, it provides methods that can be incorporated into companies’ day-to-day planning and decision making.

Plant layout is the heart of any production line because if the layout is not properly laid, there can be numerous consequences. Planning a layout for an SME is the most crucial and tedious job for a manufacturer because it is time-consuming and sometimes a costly process. Therefore, there is a need to choose appropriate methods to overcome certain problems and plan a good layout for the SMEs.The purpose of this thesis report is to explore methods that can help to plan the layout according to the requirements provided by the SME. This involves a detailed study conducted to understand the processes at the case company. However, change of layout is not just making changes to the existing layout, but some SMEs must plan a completely new layout where they can start from scratch. Similarly, in this case, a Swedish manufacturing company REHOBOT Rotex AB has provided all the data required for planning the layout. This leads the authors to study the entire production flow to know the current layout and identify the problems that exist in the plant. The approach of this thesis was a case study where the company has provided all the details like documents, current layout plans, and video recording of the plant.The study shows that maximum time is spent in the replenishment of storage and unnecessary movement of materials between the machines in the current facility. These activities can be classified as Nonvalue added or just can be addressed as waste. Therefore, there is a need to implement lean tools and use the SLP method to plan the new layout systematically. This method led to form alternative layout plans that consisted of changes made depending on the current layout. These changes will fetch the advantages and disadvantages that can further help in evaluating the alternatives using WFA. Once evaluated, the layout that turned out to be the best will be suggested and presented to the case company.

La capacidad y las buenas prácticas de producción son base para el desarrollo de las empresas y más con la competitividad actual. Por ello, el caso de estudio presentado analiza las operaciones de una MYPE peruana del sector plástico, que habría dispuesto previamente mudarse a una nueva planta. En base a un diagnóstico se identificó un déficit en su capacidad de producción con costos representativos equivalentes al 9% de su facturación anual, derivados de la falta de máquinas e ineficiencias, las cuales aun siendo solucionadas no permitirían satisfacer la demanda, por lo que se confirmó que la decisión de la empresa era correcta. De tal forma, se planteó un proyecto que permitiría el diseño de las nuevas instalaciones de la empresa en un local de mayores dimensiones, con el objetivo de optimizar su capacidad de producción y evitar que las malas prácticas detectadas en la actualidad se repitan, validando su viabilidad mediante un prototipo virtual. Asimismo, en base a los cálculos se lograría aumentar la capacidad instalada en 53.5%, superando a la demanda proyectada dentro de tres años en un 24.90 %, lo que permitiría un mayor crecimiento organizacional en el futuro. / The capacity and good production practices are the basis for the development of companies and more with the current competitiveness. Therefore, the case study presented analyzes the operations of a Peruvian MSE in the plastics sector, which would have previously arranged to move to a new plant. Based on a diagnosis, a deficit in its production capacity was identified with representative costs equivalent to 9% of its annual turnover, derived from the lack of machines and inefficiencies, which, even being solved, would not allow to satisfy the demand, therefore confirmed that the company's decision was correct. In this way, a project was proposed that would allow the design of the company's new facilities in a larger premises, with the aim of optimizing its production capacity and preventing the bad practices detected at present from being repeated, validating their viability through a virtual prototype. Furthermore, based on the calculations, it would be possible to increase the installed capacity by 53.5%, surpassing the projected demand in three years by 24.90%, which would allow greater organizational growth in the future. / Trabajo de investigación