Operations improvement methodologies have been adopted by manufacturing companies since the early 20th century. Japanese manufacturers were able to offer products of high quality and efficient production costs through systems such as Lean. Manufacturers in the West soon adopted systems of their own thereafter. Operations Excellence is a generic term used to describe such systems, and can be described as a management system delivering competitiveness through the continuous improvement of operational performance. This study provides a critical review of the implementation of an Operations Excellence program by examining the system adopted by a petrochemical company in South Africa. The review allowed the implementation shortcomings to be identified so that resolutions could be suggested, thus facilitating successful utilisation of the system. An evaluation of Operations Excellence programs utilised globally and at the case study organisation was carried out as part of a literature study. This research included the critical success factors and lessons learnt from the systems employed by others. Experimental field work was carried out to allow the critical evaluation of the implementation in the case study. The experimental method utilised a combination of qualitative and quantitative methods for data collection. The primary research instrument was a questionnaire designed to examine the degree in which critical success factors and Operations Excellence requirements were present in the organisation. The implementation shortcomings were successfully identified through the experimental work undertaken. These shortcomings, together with the review of the available literature on Operations Excellence, allowed for the proposition of recommendations with the objective of successful utilisation of Operations Excellence programs for large enterprises. / MIng (Development and Management Engineering), North-West University, Potchefstroom Campus, 2014

Operations improvement methodologies have been adopted by manufacturing companies since the early 20th century. Japanese manufacturers were able to offer products of high quality and efficient production costs through systems such as Lean. Manufacturers in the West soon adopted systems of their own thereafter. Operations Excellence is a generic term used to describe such systems, and can be described as a management system delivering competitiveness through the continuous improvement of operational performance. This study provides a critical review of the implementation of an Operations Excellence program by examining the system adopted by a petrochemical company in South Africa. The review allowed the implementation shortcomings to be identified so that resolutions could be suggested, thus facilitating successful utilisation of the system. An evaluation of Operations Excellence programs utilised globally and at the case study organisation was carried out as part of a literature study. This research included the critical success factors and lessons learnt from the systems employed by others. Experimental field work was carried out to allow the critical evaluation of the implementation in the case study. The experimental method utilised a combination of qualitative and quantitative methods for data collection. The primary research instrument was a questionnaire designed to examine the degree in which critical success factors and Operations Excellence requirements were present in the organisation. The implementation shortcomings were successfully identified through the experimental work undertaken. These shortcomings, together with the review of the available literature on Operations Excellence, allowed for the proposition of recommendations with the objective of successful utilisation of Operations Excellence programs for large enterprises. / MIng (Development and Management Engineering), North-West University, Potchefstroom Campus, 2014

This thesis discusses and demonstrates the benefits of simulating and optimising a manufacturing control system in order to improve flow of production material through a system with high variety low volume output requirements. The need for and factors affecting synchronous flow are also discussed along with the consequences of poor flow and various solutions for overcoming it. A study into and comparison of various planning and control methodologies designed to promote flow of material through a manufacturing system was carried out to identify a suitable system to model. The research objectives are; • Identify the best system to model that will promote flow, • Identify the potential failure mechanisms within that system that exist and have not been yet resolved, • Produce a model that can fully resolve or reduce the probability of the identified failure mechanisms having an effect. This research led to an investigation into the main elements of a Drum-Buffer-Rope (DBR) environment in order to generate a comprehensive description of the requirements for DBR implementation and operation and attempt to improve the limitations that have been identified via the research literature. These requirements have been grouped into three areas, i.e.: a. plant layout and kanban controls, b. planning and control, and c. DBR infrastructure. A DBR model was developed combined with Genetic Algorithms with the aim of maximising the throughput level for an individual product mix. The results of the experiments have identified new knowledge on how DBR processes facilitate and impede material flow synchronisation within high variety/low volume manufacturing environments. The research results were limited to the assumptions made and constraints of the model, this research has highlighted that as such a model becomes more complex it also becomes more volatile and more difficult to control, leading to the conclusions that more research is required by extending the complexity of the model by adding more product mix and system variability to compare results with the results of this research. After which it will be expected that the model will be useful to enable a quick system response to large variations in product demand within the mixed model manufacturing industry.

Orientador: Marcos Valerio Ribeiro / Resumo: Ambientes industriais são altamente competitivos. Fatores como a agilidade, a flexibilidade, a prestação de serviços, a qualidade e preços são as vantagens competitivas procuradas pelas organizações. Neste cenário, as otimizações propostas que abordam tais fatores são de particular interesse para o planejamento de processos. O procedimento proposto tratado é o resultado líquido direto e o aumento da competitividade no mercado de uma determinada empresa, visando que sua estrutura financeira seja a mais saudável possível. Este trabalho tem como objetivo auxiliar e desenvolver um procedimento padrão de verificação do nível de rentabilidade de uma empresa e ainda, se esta empresa tem a probabilidade de tornar-se mais rentável. Tal procedimento visa atingir um segundo objetivo no sentido de maximizar os recursos já existentes na própria organização. O aspecto chave desta pesquisa diz respeito à utilização de máquina com tempos ociosos e plena utilização de todos os sistemas disponíveis de fábrica. Quando a ociosidade destas máquinas utilizadas em pleno processo produtivo, é possível concluir como resultado das aplicações realizadas, uma maximização dos recursos propiciando o melhor resultado da organização. Esta ociosidade quando não apurada com a devida acurácia é lançada indevidamente nos custos dos produtos, fazendo com que a empresa possa perder competitividade / Abstract: Industrial environments are highly competitive. Factors such as agility, flexibility, service delivery, quality and prices are the competitive advantages sought by organizations. In this scenario, the proposed optimizations that address such factors are of particular interest for process planning. The proposed procedure is the direct net result and the increase of the competitiveness in the market of a certain company, aiming that its financial structure is as healthy as possible. This work aims to assist and develop a standard procedure for verifying the level of profitability of a company and still, if this company has the probability of becoming more profitable. This procedure aims to achieve a second objective in order to maximize resources already existing in the organization itself. The key aspect of this research concerns the use of idling machines and full utilization of all the systems available from the factory. When the idleness of these machines used in full productive process, it is possible to conclude as a result of the applications made, a maximization of the resources propitiating the best result of the organization. This idleness when not verified with the correct accuracy is improperly thrown into the costs of the products, causing the company to lose competitiveness / Doutor

Identificar a meta, pensar na empresa como um todo e não como um conjunto de partes isoladas, reconhecer e aumentar a capacidade da restrição, são etapas necessárias para a implementação da Theory of Constraints (TOC). Essa utilização, seja por meio de raciocínio lógico ou por meio da metodologia Tambor-Pulmão-Corda, visa racionalizar os processos nas organizações e criar novas abordagens que permitam alavancar a competitividade das organizações. Este trabalho parte da intenção de abordar os princípios e as práticas da Teoria das Restrições, identificando e analisando o impacto da implantação da TOC na gestão da produção. Neste contexto, a pesquisa apresenta um enfoque tanto exploratório, quanto descritivo. Pode ser considerado exploratório, uma vez que a revisão da literatura servirá como referência central para as seguintes discussões - a partir da implantação da TOC, quais as mudanças geradas no processo de gestão de uma empresa, quais as alterações nas rotinas de trabalho, qual a reação da equipe envolvida no processo. É descritivo, por meio da descrição e análise de estudos de caso. Sendo assim, pretende-se a partir do levantamento e avaliação do desempenho organizacional e de pesquisa realizada junto a empresas conceituadas, identificar como essas organizações vêem o papel e importância da TOC, sua relevância, efetividade, bem como os aspectos importantes para sua implementação. / Identifying the goal, thinking of the company as a whole and not as a set of isolated parts, to recognize and to increase the capacity of restriction, are necessary stages for the implementation of the TOC (Theory of Constraints). This utilization, be it by means of logical reasoning or by means of methodology Drum-Buffer-Rope, aims to rationalize the processes in the organizations and to create new approaches that allow for the organizations to leverage competitiveness. This article aims to approach the principles and practices of the Theory of Constraints, identifying and analyzing the impact of implantation of TOC in the production administration. In this context, the research presents an exploratory focus as well as a descriptive one. It can be considered exploratory, being that the literature revision will serve as the main reference for the following discussions - from TOC implantation, what changes are generated in the administration process of a company, what are the alterations in the working routines, what is the reaction of the team involved in the process. It is descriptive, by means of description and analysis of case studies. Thus, it is intended from the rising of information and performance evaluation and of research accomplished along with relevant companies, to identify how these organizations see the role and importance of TOC, its relevance, effectiveness, as well as the important aspects for its implementation.

A definição do mix de produção proporciona a alocação dos recursos produtivos no processo de manufatura, visando a otimização da sua utilização e do desempenho do sistema produtivo o que, por sua vez, em um nível gerencial, norteia a performance da organização. Entretanto, apesar de sua importância, a definição do mix de produção é um problema do tipo NP-Completo, ou seja, de difícil solução. Assim, com o auxílio da Teoria das Restrições - TOC, muitas heurísticas construtivas têm sido apresentadas para fazer frente a esse problema. Nesse sentido, o objetivo deste trabalho é propor uma nova heurística, denominada TOC-SN, baseado na TOC e no problema da mochila, que proporcione melhores soluções quando comparada com as principais heurísticas apresentadas na literatura, a TOC-h de Fredendall e Lea e a TOC-AK de Aryanezhad e Komijan. Para realização dessa comparação foram realizadas experimentações computacionais visando identificar o mix de produção que possibilitasse o maior ganho possível, em situações nas quais não há recursos disponíveis para produção de todos os produtos. Como resultado, observou-se que a TOC-SN obteve uma solução mais satisfatória quando comparada à aplicação das outras heurísticas e à solução ótima o que, em conclusão, evidencia a sua importância na definição de mix de produção. / The product-mix decision make possible to distribute the resources in the manufacture process, with the objective of optimizing the use of the resources and the performance of the productive system. This problem is well-known for being NP-Complete and therefore, most contributions to the topic focus on developing heuristics able to obtain good solutions for the problem in a short CPU time. Then, the objective in this thesis is to propose a new constructive heuristic or the TOC-SN based on the Theory of Constraints - TOC and on the Knapsack Problem that indicates better solutions than the TOC-h heuristic proposed by Fredendall and Lea and the TOC-AK heuristic proposed by Aryanezhad and Komijan. Experimentation computational was accomplished with the objective of testing the heuristics in the definition of product mix that made possible the best throughput in situations with scarcity of productive resources. The computational results indicate that the proposed heuristic obtains better results than the existing heuristic.

Com um quinto da água doce do planeta, o sistema fluvial da Amazônia apresenta um enorme potencial para piscicultura. De acordo com a FAO, em função das suas condições geográficas, o Brasil é um dos poucos países que tem condições de atender à crescente demanda mundial, podendo tornar-se um dos maiores produtores de peixes do mundo. A observação desse potencial amazônico motivou o desenvolvimento desta pesquisa que se debruça sobre a questão da competitividade da cadeia produtiva de Arapaima gigas, o pirarucu da Amazônia brasileira. As pesquisas de campo levaram ao mapeamento de duas cadeias: a cadeia extrativista e a piscicultura. A abordagem sistêmica permitiu a verificação das características dos atores e as bases sob as quais as transações se estabelecem. À luz da teoria das restrições foram identificados os gargalos que impedem a competitividade do sistema, inclusive alertando para os recursos com restrição de capacidade. Comprovou-se que a falta de uma cadeia produtiva devidamente organizada pode provocar graves prejuízos a determinados elos, enquanto outros membros aproveitam-se de ações oportunistas para ampliar suas margens de lucro. Da mesma forma, a ausência de uma cadeia produtiva completa impede a fixação do valor gerado na região de origem das matérias-primas. No entanto, também foi possível comprovar que há possibilidade de desenvolver o extrativismo atribuindo valor econômico aos recursos naturais e gerando renda para a comunidade local. Além de apresentar o panorama do setor na região delimitada, este estudo culminou em reflexões capazes de orientar políticas públicas para o desenvolvimento de cadeias produtivas completas na região da Amazônia brasileira. / With roughly a fifth of the planet\'s fresh water, Amazon fluvial system has a huge potential for fish farming. According to FAO, Brazil is one of the few countries that is able to meet the growing global demand and could become one of the world\'s largest fish producer. This research was motivated by the acknowledge of this huge potential. The focus of analysis is related to the competitiveness of the Arapaima gigas productive chain, a large fish called the \"pirarucu of Brazilian Amazon\". Field research led to the mapping of two distinct chains: the extractivism-based chain and fish farming chain. The systemic approach allowed the researcher to gain knowledge on players individual characteristics and on the ground under which the transactions are established. In light of the theory of constraints it were identified some bottlenecks that hinder system competitiveness, including a warning against some resources with capacity constraint. It was found also that the lack of a properly organized production chain can cause serious damage to certain links, while other members take opportunistic advantage. Likewise, the absence of a complete production chain prevents locals to properly accrue all value generated in the region of origin of the raw materials. However, it was also possible to demonstrate that it is possible use the economic potencial of Amazonian Region delivering economic value to local community. In addition, this study also contributes ellaborating some reflections to support public policies concerned with the development of a complete production chain in Brazil\'s Amazon region.

Made available in DSpace on 2016-08-10T10:40:16Z (GMT). No. of bitstreams: 1 FABIO PEGORARO.pdf: 2667580 bytes, checksum: 6fc5c5ce22768636449f0666fff664c1 (MD5) Previous issue date: 2012-09-05 / This paper presents the results obtained with the application of computer simulation and theory of constraints to reduce the waiting time for urgent care at the Hospital Regional Gurupi (HRG). The simulation model focuses on the patients in a state of emergency and urgency. Patient in a state of emergency can not remain in the queue and should be treated immediately, as the patient in a state of emergency can stay up to 30 minutes in a queue. The methodology used is exploratory case study techniques supported by semi-structured interviews and questionnaires administered to managers and hospital doctors. The actual model (scenario 1) the hospital is simulated using PROMODEL® software. Two more scenarios are created following the process of continuous improvement of the theory of constraints and simulated using PROMODEL®. It is observed that through the application of computer simulation combined with the theory of constraints, the managers of the Emergency Room (ER) of HRG have adequate information to manage it in order to reduce the waiting time for urgent and emergency care. / Este trabalho apresenta os resultados obtidos com a aplicação da simulação computacionale teoria das restrições para reduzir o tempo de espera por atendimento de urgência no Hospital Regional de Gurupi (HRG). O modelo de simulação tem foco nos pacientes em estado de urgência e emergência. Paciente em estado de emergência não pode permanecer em fila de espera e deve ser atendido imediatamente, já o paciente em estado de urgência pode permanecer até 30 minutos em uma fila de espera. A metodologia usada é exploratória com estudo de caso apoiada em técnicas de entrevista semi-estruturada e questionários aplicados aos gestores e médicos do hospital. O modelo real (cenário 1) do hospital é simulado utilizando o software PROMODEL.® Mais dois cenários são criados seguindo o processo de melhoria contínua da teoria das restrições e simulados utilizando o software PROMODEL®. Observa-se que através da aplicação da simulação computacional aliada à teoria das restrições, os gestores do Pronto Socorro (PS) do HRG possuem informações adequadas para geri-lo de forma a reduzir o tempo de espera por atendimento de urgência e emergência.

Made available in DSpace on 2016-08-10T10:40:17Z (GMT). No. of bitstreams: 1 Donizeti Padilha de Souza.pdf: 2689123 bytes, checksum: 28a86b4d37447c3f9f3f3d8368b3f293 (MD5) Previous issue date: 2012-08-28 / The various theories of production management have been suggesting improvements and also presenting achievements made by organizations in their multiple productive activities. In this sense, it is necessary to ensure that the proposed changes actually take place, the results perpetuate and the gained knowledge is reported. Thus, research methods that involve a larger number of participants, such as the action research, involve these members and consequently, generate a greater commitment of those who take part in the process, then the learning takes place simultaneously with the practice. In the current context of global media models, the sector of Newspapers suffers fierce competition. This study aimed to observe the processes of change made in the industrial area of a daily periodical company in the city of Goiânia through the action research method and based on the Theory of Constraints combined with other production methods which are described in the body of this paper. The deployed changing processes named RETROFIT had the objective of making the company in which the research took place into a more competitive organization and, above all, more agile in their manufacturing processes of printed materials in order to meet market demand for their products. Management focused on the constraints presented the following results: better performance for the system as a whole; better nominal capacity for the printers; an opportunity for the employees, which are directly engaged in the production process, to visualize the priorities to be observed within the process; it also highlighted the importance of preventive maintenance and an overview of the main causes in the industrial area that prevent the company to earn more money. / As várias teorias de gestão da produção têm sugerido melhorias e apresentado resultados alcançados pelas organizações em suas múltiplas atividades produtivas. Nesse sentido, é necessário garantir que as mudanças propostas sejam efetivadas, os resultados perenizados e os conhecimentos adquiridos divulgados. Assim, métodos de pesquisa que contam com um universo maior de participantes, como a pesquisa-ação, envolvem estes integrantes e, por consequência, geram maior comprometimento dos envolvidos no processo, e o aprendizado acontece simultaneamente com a prática. No atual contexto dos modelos de mídia global, o segmento Jornal sofre acirrada concorrência. Esta pesquisa objetivou acompanhar os processos de mudança realizados na área industrial de uma empresa de periódicos, na cidade de Goiânia, através do método pesquisa-ação, tendo como alicerce a Teoria das Restrições, aliada a outros métodos de produção, que estarão descritas no corpo do trabalho. Os processos de mudança implantados, denominados RETROFIT, tiveram como escopo tornar a empresa na qual se realizou a pesquisa mais competitiva e, sobretudo, mais ágil nos seus processos de manufatura dos impressos produzidos, para atender à demanda de mercado dos seus produtos. O gerenciamento com foco nas restrições apresentou como resultados: melhor desempenho para o sistema como um todo, permitiu melhorar a capacidade nominal das impressoras, propiciou aos colaboradores diretamente envolvidos na produção dos periódicos, visualizarem prioridades a serem observadas no processo, mostrou a importância da manutenção preventiva e quais são as principais causas na área industrial que impedem a empresa de ganhar mais dinheiro.

Made available in DSpace on 2015-03-05T18:39:04Z (GMT). No. of bitstreams: 0 Previous issue date: 30 / Nenhuma / A despeito de quaisquer outros objetivos que possam ter as organizações empresariais, a principal meta a ser alcançada é o lucro. Para que o lucro seja al-cançado as empresas lançam mão de estratégias que são traduzidas em passos tá-ticos e que seguem implícita ou explicitamente as orientações de uma teoria. Essa teoria é sempre uma projeção racional da realidade. A efetividade das estratégias adotadas é resultado, em primeiro lugar, da correspondência entre a teoria adotada e a realidade. A teoria adotada deve ser capaz de descrever a realidade, indicar meios de interferir nela e de fazer previsões dos resultados dessa interferência. Em segundo lugar, a efetividade das estratégias depende de uma formulação adequada para as condições particulares do meio onde ela será aplicada. Em terceiro lugar, a efetividade da estratégia depende de ações que transformem a realidade segundo os objetivos que se quer alcançar. O Programa Visão Viável da Teoria das Restri-ções é uma dessas estratégias para alavancar o crescime / In spite of any other tasks that commercial organizations have, the main goal to be reached is profit. In the aim to reach that, companies make use of strategies that are translated in tactical steps which follow implicitly or explicitly the orientation of a the-ory. This theory is always a rational projection of reality. The effectiveness of the adopted strategies results, in first place, from the correspondence between the adopted theory and the reality. The adopted theory must be capable to describe the reality, to indicate ways to intervene with it and to make forecasts of the results of this interference. In second place, the effectiveness of the strategies depends on an ap-propriated formularization adjusted for the particular conditions of the environment where it will be applied. In third place, the effectiveness of the strategy depends on objective actions that transform the reality accordingly to the tasks to be reached. The program Viable Vision of the Theory of Constraints is one of these strategi