The aim of this semestral thesis is to use the Value Stream Mapping (VSM) as visual aids to describe streamlining the production process of vibration welding machines in Emerson Industrial Automation, in Nove Mesto nad Vahom. In this thesis is contained description and comparison of the software support for the VSM. Theoretical part describes the causes of lean production and discusses the purpose of mapping of the value stream and variables associated with it.

Purpose – The purpose of the study is to explore how productivity can be improved in an assembly line in manufacturing industry. In order to fulfill the purpose, following three research questions have been formulated: 1. How can an assembly line be designed? 2. Which potential improvement areas can be found in an assembly line? 3. How can assembly line balancing be used to improve productivity? Method – A case study was performed in order to answer the research questions. A combination of quantitative and qualitative data have been collected. To build an understanding of existing theories and research within the study area, a literature study was conducted which formed a theoretical framework. Parallel to the literature study, empirical data was collected through a case study. Data collection methods included observations, document studies, time measurements and focus group meetings. The reviewed theories and the collected data were later analyzed and a result was generated. Findings – In order to improve productivity, Theory of Constraints enabled the identification of potential improvement areas. To address the improvement areas, Assembly Line Balancing was found an appropriate method. Through the case study it was found that through Assembly Line Balancing, a reduction of takt time can be achieved which opens up the possibility to increase the production volume. Also, when re-allocating operators between work tasks, a reduction in numbers of operators is possible which results in lower costs. By lowering costs and increasing production volume, improved productivity is achieved. Implications – This study presents an application of the two improvement methods Theory of Constraints and Assembly Line Balancing in a manufacturing industry. Therefore, the thesis can be used as a basis when performing improvement work related to reduction of takt time in other manufacturing industries, to gain a better understanding for the implementation of the studied methods. Limitations – One limitation of the study was the pandemic Covid-19, which enforced restrictions on the case company. This disturbed the conduction of the case study since less focus group meetings were conducted, and suggested improvements could not be tested. Another limitation was the limited study time frame. Consequently, the collected time measurements were relatively few and the study scope was delimited to only packaging activities. To increase reliability, a more extensive time frame is necessary. The analysis has been adopted to the situation at the case company. The conclusions may hence be biased, which could restrict to what extent the study can be generalized.

<div>Reviewing the literature verifies that manufacturing industries fall short of the required sustainable criteria in the system design.</div><div>One of the leading reasons behind such a failure refers to the lack of an effective system design's knowledge toward the selected solutions by benchmarking.</div><div>The Collective System Design (CSD) approach provides a countermeasure for this shortcoming by starting the design approach with a collective agreement upon the external and internal customer needs and then choosing the solutions for the system design to achieve those needs. </div><div>The general requirements and solutions to a manufacturing system are covered in the Manufacturing System Design Decomposition (MSDD) in a linear and path-dependent fashion, which is a core derivative of the CSD.</div><div><br></div><div>The CSD application in industrial case studies has been provided in this thesis to elaborate on how the CSD approach assists industries to re-design their systems in a sustainable manner.</div><div>The segregation of the tools and objectives of the system re-design in a path-dependent fashion is guided by the design principles.</div><div>The case studies described how to achieve the external customer needs of product quality, quantity, variety, and on-time delivery with a collaborative work inside the plant. </div><div>This collaboration was built up by defining the customer-supplier connection inside the plant.</div><div>Cell re-design and balancing of operations with a well-defined standard work is also elaborated in this research to help produce what is needed to be shipped today with the least amount of waste in the system.</div><div>The after system redesign MSDD questionnaire analysis at these industries have shown that the industries successfully satisfied their system needs in a sustainable manner. </div><div><br></div><div>In those case studies, an internal customer need for a safe working environment was also brought to light and the CSD approach was introduced and applied to achieve the associated requirements of safety. </div><div>As the original MSDD lacked the requirements and solutions for the safety component, an updated version of the MSDD has been proposed to incorporate </div><div>the safety branch to the MSDD.</div><div>In addition, some enhancements to the current version of the MSDD have been made for a clearer and more thorough understanding of the system design.</div>

Orientador: Antonio Batocchio / Dissertação (mestrado profissional) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-11T07:20:48Z (GMT). No. of bitstreams: 1 Fagundes_RenatoAlexandre_M.pdf: 1173048 bytes, checksum: f9c42d8865a1d2718c308d673b82bd20 (MD5) Previous issue date: 2007 / Resumo: Este trabalho tem como objetivo a implementação de um processo cadenciador (ou puxador) na linha de produção de uma indústria fabricante de placas de circuito impresso rígidas, focando principalmente na implantação de um sistema cadenciador para que o fluxo de produção flua de uma maneira cadenciada e limpa para atender uma determinada família de produtos de placas de circuito impresso rígido (não metalizadas ¿simples face¿ e metalizadas ¿dupla face¿). A montagem da célula de produção para o estudo foi desenvolvida a partir da análise da técnica de mapeamento de fluxo estendido para se obter a melhor produtividade do sistema e atender as demandas do cliente final. A existência de algumas formas de variabilidades nos tempos takt, balanceamento de operadores, tempo para troca de modelos e dimensionamento do ciclo de máquinas foram estudadas e apresentadas buscando sempre uma otimização do fluxo contínuo dentro do processo cadenciador. Através das técnicas de mapeamento de fluxo de valor foi montado um mapa de estado atual e futuro o qual nos permite visualizar de uma maneira mais clara as correções propostas. Palavras chaves: Manufatura enxuta, Mapeamento de Fluxo de Valor, Tempo Takt, OBC / Abstract: This work has as objective the implementation of a pacemaker process in the line of production of an industry manufacturer of rigid printed circuit board, where the major is on the implantation of a pacemaker process allowing a production flow clean and smoth for one definitive product family of the printed circuit board (not metallized "single face" and metallized "double face"). The assembly of the cell of production for the study was developed from the analysis of the technique of Mapping Stream Value to get the best productivity of the system and to take care of the demands of the final customer. The existence of some forms of variabilities like : takt time, balancing of operators, time for exchange of models and sizing of the cycle of machines had been studied and presented searching always an optimization of the continuous flow inside of the pacemaker process. Through the techniques of Mapping Stream Value from the current state to future state was mounted which in allows them to visualize in a clear way of the corrections proposals. Key words- Lean Manufacturing, Value Stream Mapping, Takt Time, OBC / Mestrado / Planejamento e Gestão Estrategica da Manufatura / Mestre em Engenharia Mecânica

No description available.

LEAX Falun är intresserad av möjligheten att införa ett taktat system för monteringsbanan A i en närmast framtid. I ett otaktat nuläge döljs problem på monteringsbanan och LEAX Falun vill veta om effekterna av ett taktat flöde. Målet med examensarbetet var att utvärdera och ta fram potentiella vinster med ett taktat flöde. I samband med det skulle även en simuleringsmodell för hur ett taktat flöde kan se ut tas fram samt de parametrarna som styr det taktade resultatet. Lösningsmetoder som tidtagningar, simulering, benchmarking, intervju och informationsinsamling har legat som grund till resultatet. Med hjälp av utvalda teorier samt resultatet som analyserades har examensarbetet visat att det är en långsiktig lönsamhet med ett taktat flöde. Monteringsbanan A kan klara en teoretisk takttid på tre minuter idag. De parametrarna som påverka det taktade flödet är takttid, flexibilitet mellan operatörer, Andonpersonal, visualisering, produktionsplanering samt ledarskap. Simuleringsmodellen är förenklad och visar hur ett taktat flöde med tre minuters takttid kan se ut. De huvudsakliga potentiella vinsterna med ett taktat flöde har identifierats som utjämning av produktion, synliggöra avvikelser till ytan för minskning av slöseri samt en bättre balansering av arbetsinnehåll och resurser. För att en implementering av ett taktat system ska fungera ställs det stora krav på ledarskap att aktivt engagera och motivera medarbetarna och sänder ut Lean budskap. / LEAX Falun are interested in the possibility of introducing a takt flow system on the assembly line A soon. In the current situation where the assembly process occurs without a continuous flow, some problems remains unseen. Therefore, LEAX Falun want to know the effects of a takt flow system. The aim of the thesis was to evaluate and present potential benefits with a takt flow system. In conjunction with that, a simulation model will be presented to show how a takt flow system looks like. An analysis of which parameters would have an impact on the takt time will also be presented. Methods such as timing, simulation, benchmarking, interviewing and information gathering have contributed crucial information for the results and conclusion part. With the help of selected theories and the analyzed results, the thesis has shown that it is a long-term profitability investment with a takt flow system. The assembly line A has shown that it can run at a theoretical takt time of three minutes but in reality, some parameters must be taken into consideration such as flexibility between operators, Andon-crew, visualization, production plan and the leadership of the organization. The simulation model is simplified and demonstrates how a takt flow system with a takt time can look like. The key benefits of a takt flow system with a takt time have been identified as continuous flow of production, easier to detect problems for waste reduction and a better balance of workload and resource usage. For a takt time system to be successful, the leadership plays an important role. They must actively make employees feel involved and motivated and constantly sending out Lean messages

Submitted by Marcia Silva (marcia@latec.uff.br) on 2016-05-02T20:33:14Z No. of bitstreams: 2 dissert Oydil Cesar de Figueiredo.pdf: 4453669 bytes, checksum: e33d72aa1c70ea37d37ddcdc603b8c51 (MD5) dissert Oydil Cesar de Figueiredo.pdf: 4453669 bytes, checksum: e33d72aa1c70ea37d37ddcdc603b8c51 (MD5) / Made available in DSpace on 2016-05-02T20:33:14Z (GMT). No. of bitstreams: 2 dissert Oydil Cesar de Figueiredo.pdf: 4453669 bytes, checksum: e33d72aa1c70ea37d37ddcdc603b8c51 (MD5) dissert Oydil Cesar de Figueiredo.pdf: 4453669 bytes, checksum: e33d72aa1c70ea37d37ddcdc603b8c51 (MD5) Previous issue date: 2015-11-30 / O presente trabalho descreve o processo de gestão de melhoria das operações produtivas de fabricação, apresentando um caso prático de aplicação do conceito de produção com foco na eliminação dos desperdícios em uma indústria automotiva. O exemplo aludido relata o processo de planejamento, execução, manutenção e controle de uma sequência de três projetos de melhoria de uma célula de montagem de uma indústria de autopeças, situada na região Sul Fluminense no Rio de Janeiro, entre os anos de 2008 e 2014. A pesquisa teve o objetivo de estudar os métodos e ferramentas Lean Manufacturing na indústria de autopeças identificando os fatores restritivos e facilitadores no processo de aplicação dessa filosofia. Com os dados coletados foi possível verificar vantagens e desvantagens da utilização de diferentes conceitos logísticos, distintas configurações de trabalho padronizado e layout. Por meio de uma revisão documental e uma pesquisa-ação, verificaram-se ganhos significativos ao adotar os conceitos propostos, elevando a produtividade da linha estudada em 92%, quando comparado com o ano inicial, demonstrando-se que as técnicas propostas efetivam-se em vantagem estratégica competitiva em relação a outras empresas concorrentes que trabalham sob a ótica da produção em massa. Como resultados adicionais, a pesquisa fornece informações sobre a sequência de uso das ferramentas oferecendo um auxílio para empresas que buscam a implantação dessa filosofia, disseminando, assim, o conhecimento sobre a filosofia Lean Manufacturing / This study describes the continuum improvement process of productive manufacturing operations, showing an applying case of the concept of production with a focus on eliminating waste in an automotive industry. The example used describes the process of planning, execution, maintenance and control of a sequence of three improvement projects in one assembly line of an automotive parts industry, located in the Rio de Janeiro, between 2008 and 2014. The research aimed to study the methods and Lean Manufacturing tools in the automotive industry by identifying the blocks and facilitators factors in this philosophy application. With the collected data were verified advantages and disadvantages of using different logistics concepts, different standardized work settings and layout. Through a documentary review and action research, have been checked significant gains by adopting the proposed concepts, increasing line productivity by 92%, when compared with the initial year, showing that the applied technical become more effective than the companies that work as pushed production. As additional results, the survey provides information on the use sequence of tools offering support to companies that are implementing this philosophy

This study is conducted at Scania, a globally leading company that manufactures trucks and delivers transport solutions to customers around the globe. In this study, the end flow of the chassi manufacturing was mapped in order to identify and eliminate wastes and bottlenecks, with the help of lean principles and discrete event simulation (DES) software. The assembly line consists of a make-to-order production head line that sends out semi-finished trucks to the end flow. The end flow is thereby codependent on the output from the head line. A synchronized tacted flow would minimize the wait in the stations, which is considered a waste in production, and enhance quality of work as deviations become more visible. The complexity of the production system has however made the department disregard the usage and implementation of simulations tools for improvement and decision making. The aim of this study was to evaluate the applicability and feasibility of DES as a tool for waste elimination, to increase throughput in a complex system and for investigating a better ratio between the takt times of the codependent assembly lines. This was done by developing future scenarios with different configurations of the model, studying how the parameters' behavior change in DES. Recommendations for reaching more effective codependent assembly lines with the help of DES were developed, analyzing the benefits and challenges of using simulation solutions for future decision making. The study offered useful insights and practical guidelines for companies with complex codependent assembly lines, wanting to use DES to implement lean principles. Five different improvement scenarios were tested and it was concluded that an increased number of buffer spots would have the largest impact on the throughput. An optimized takt time for a maximized throughput was also possible to identify with an enumeration method with scenarios. The drawback of DES for complex codependent lines was found to be the inability to consider all surrounding factors such as safety, ergonomics, quality and communication, which makes it a less applicable tool for waste elimination. The benefit of the DES simulation was the ability to manage complexities such as; different takt times between lines; gaps that occur in the production because of trucks removed from the head line; the interplay of the various inflows merging; the additional time to receive trucks from the reparation department; and stop times that cause waiting time at the production line. It was therefore considered an applicable tool for deciding the takt time for codependent lines. / Denna studie är genomförd på Scania, ett globalt ledande företag som tillverkar lastbilar och levererar transportlösningar till kunder runt om i världen. I denna studie kartlades slutflödet av chassitillverkningen för att identifiera och eliminera slöserier och flaskhalsar, med hjälp av leanprinciper och Discrete Event Simulation (DES). Produktionslinan består av en make-to-order huvudlina som skickar ut halvfärdiga lastbilar till slutflödet. Slutflödet är därmed beroende av utflödet från huvudlinan. Ett mer synkroniserat taktat flöde skulle minimera väntetider på stationerna, vilket anses vara slöseri i produktionen, och förbättra kvaliteten på produkterna. Produktionssystemets komplexitet har dock fått avdelningen att bortse från användningen och implementeringen av simuleringsverktyg för beslutsfattande. Målet med denna studie var att utvärdera användbarheten och genomförbarheten av DES som ett verktyg för att eliminera slöserier för att öka antal producerade produkter i ett komplext system, för att undersöka en bättre relation mellan takttider för olika linor. Detta gjordes genom att utveckla framtidsscenarier med olika konfigurationer av modellen där olika parametrarnas beteende och förändring studerades. Rekommendationer för att nå mer effektiva samberoende monteringslinjer med hjälp av DES utvecklades, där fördelarna och utmaningarna med att använda simuleringslösningar för framtida beslutsfattande analyserades. Studien gav insikter och praktiska förslag för företag med komplexa samberoende monteringslinjer, som vill använda DES för att implementera lean-principer. Fem olika förbättringsscenarier testades och resultatet visade att ett ökat antal buffertplatser skulle ha störst påverkan på antal producerade produkter. En optimerad takttid för att maximera antal producerade bilar var också möjlig att identifiera med en numerisk analys där olika intervall av takttider testats i olika scenarier. Nackdelen med DES för komplexa produktionsflöden visade sig vara oförmågan att ta hänsyn till olika omgivande faktorer som säkerhet, ergonomi, kvalitet och kommunikation. Detta gör det till ett mindre användbart verktyg för att mäta effekten av att eliminera slöserier. Fördelen med DES-simuleringen var förmågan att hantera komplexitet såsom; olika takttider mellan olika flöden; luckor som uppstår i produktionen på grund av borttagna lastbilar från huvudlinjen; samspelet mellan de olika inflödena som slås samman; den extra tiden för att ta emot lastbilar från andra avdelningar; och stopptider som orsakar väntetid vid produktionslinjen. Därmed ansågs DES vara ett användbart verktyg för att bestämma takttiden för komplexa flöden.

This thesis deals with the current state of assembly workplace for prefabrication in selected company. Using lean manufacturing principles it describes and subsequently eliminating all forms of waste that occur in the workplace. Part of the project is to design a new layout of the manufacturing cell, operation balancing and standardize the work of operators in the process. The project aims to achieve the planned production volumes at the same or lower operating costs.

Anecdotal data affirms that companies applying Lean Six Sigma in their operations not only deliver higher quality products and services, but also obtain superior financial results. The goal of this research was to empirically verify anecdotal data. The study proposed to analyze a group of publicly traded manufacturing companies with the intent of verifying if a correlation exists between companies being lean and the attainment of superior returns on investments. The researcher performed a series of statistical tests comparing key Financial Performance Indicators (FPI) extracted from annual reports (10-K) from a large pool of companies. The outcome of this study showed that superior financial rewards result from a systematic application of lean and quality tools. At the conclusion of this thesis we verified that companies having a business model that stimulates a high level of communication between them and their markets - because they are lean - obtained substantially higher financial advantages when compared to companies that still followed a more traditional mode of production. The results also revealed that lean companies obtained on average Return on Invested Capital (ROIC) 10% higher than mass producers. Therefore, companies wanting to strategically invest their capital should consider Lean Six Sigma as a source of competitive advantage. Another strategic insight derived from this study was the recognition of signs of a smart business. Potential investors should look for the presence of lean and quality improvement programs as one sign that capital is being wisely invested to generate value. Another sign is how well historically ROIC have performed against Weighted Average Cost of Capital (WACC). The research revealed that, on average, lean companies had ROIC of 16%. Assuming that the hurdle rate (WACC) for most companies is near 10%, having ROIC of 16% is an incentive to become lean, thus allowing such companies to create value for their shareholders. Finally, we learned that many factors affect ROIC, namely, brand equity, market positioning, patents, core competency, innovation, leadership, etc. However, the presence of a Lean Six Sigma program in a manufacturing business was a strong positive factor impacting ROIC.