Lean manufacturing has seen its creators, Toyota, rise from insignificance in the middle of the previous century, to the biggest selling car manufacturer in the world today. Another Japanese car manufacturer, Honda, which has also been practising the principles of lean avidly during the last few decades, has also made huge strides towards becoming a dominant force in the car market. These Japanese companies‟ adoption of lean has seen many of their mass producing United States (US) and European counterparts struggle for survival. Maynard (2003:10) predicted that by the end of the decade, at least one of the „Big Three‟ auto makers in the US – Chrysler, Ford, and General Motors (GM) – would be forced to undertake significant restructuring to continue in operation. At the time of this writing all indications are that this prediction will come true. GM is in the process of major shareholding restructuring in an attempt to keep the company afloat, having run up insurmountable debts in the face of the current global economic downturn. Adopting the lean methodology has become a matter of necessity. The continued use of mass production methods alone is no longer viable; companies need to also employ lean methods intelligently in order to remain competitive. This study is regarded as a crucial endeavour to assist operations managers of manufacturing concerns in developing lean implementation strategies which will maximise the benefits to the organization.

This thesis is focused on the suggestions for the application of maintenance department optimization concept -- Total productive maintenance, in the context of wider concept of lean manufacturing, in the BAEST company. The content of the thesis is to get acquainted with the theoretical background of the lean manufacturing and maintenance, analysis of the current state at the company's maintenance department reflecting the described theoretical background, identification of the potential for improvements by comparing the current state with the theoretically ideal state and coming up with individual recommendations for improvements of the maintenance department in order to make it better and more effective and efficient.

This thesis deals with the productivity of enterprise, the possibilities of its measurement and increasing productivity through the total productive maintenance. The theoretical part firstly focuses on the measuring total productivity in homogeneous and heterogeneous production and calculation of partial productivities of each production factor. Secondly, it deals with the concept of a total productive maintenance as one of the possible approaches to increasing productivity. In the practical part the analysis of productivity for the years 2004 to 2010 is made and evaluated the use of approaches and tools of total productive maintenance in specific enterprise.

[EN] This thesis explores the difficulty in implementing TPM (Total Productive Maintenance) and through the analysis of the existing literature: - Define a proposal to establish which is the most suitable TPM implementation model and the key development objectives that should be reached in each step. - Define an exhaustive list of facilitators and barriers that influences the TPM, defining hierarchical links that govern them and their similarities with the facilitators for continuous innovation. - Define the relationships between the facilitators and the steps of the proposed model, through the assessment of the impact on their development objectives and the existing hierarchical links between facilitators. In addition, it pinpoints that the difficulty of implementing TPM can be reduced by the use of two suggested questionnaires. The first is approaching the TPM implementation model and the second is more focused on the TPM facilitators. Both intend to cover the lacks in the existing development models and methodologies and be a complement to guide the personnel in charge of the TPM implementation. Through a longitudinal analysis, this thesis validates that the suggested questionnaires are suitable for their application in a company, demonstrating how the improvement of the items described in these questionnaires or proposed guidelines are linked with an improvement in the TPM implementation results. It concludes that the use of these questionnaires does not interfere or harm the development of the implementation methodologies, but reinforce them by focusing on the vision and the implementation efforts, supporting the relevant aspects to perform in the right way. It also addresses the fact that the enhancement of facilitators due to their hierarchical links improves the sustainability and reduces the need of periodic revivals of the whole TPM implementation process. / [ES] La presente tesis doctoral profundiza en la dificultad que supone la implantación del TPM (Total Productive Maintenance) y a través del análisis de las publicaciones existentes: - Elabora una propuesta que concreta cual es el modelo de implantación del TPM más adecuado y los objetivos de desarrollo fundamentales que se deberán de conseguir en cada paso. - Define una relación exhaustiva de facilitadores y barreras que influyen sobre el TPM, definiéndose las relaciones jerárquicas que los regulan y sus semejanzas con los facilitadores propios de la innovación continua. - Define las relaciones entre los conjuntos de facilitadores y los pasos de modelo propuesto, a través de la valoración del impacto que pueden tener sobre sus objetivos de desarrollo y la relación de jerarquías existente entre los facilitadores. Así mismo, concreta que la dificultad que presenta la implantación del TPM, puede reducirse mediante el uso de dos cuestionarios propuestos, uno de aproximación al modelo de implantación del TPM y otro de aproximación a los facilitadores del TPM, que ayuden a suplir las carencias de los modelos y metodologías de desarrollo existentes y sirvan como complemento que oriente al personal de planta, encargado de implantar el TPM, en el buen camino. A través de un análisis longitudinal, en la presente tesis doctoral se valida que los cuestionarios elaborados son adecuados y pueden ser utilizados en una empresa real, mostrando como una mejora de los ítems descritos en estos cuestionarios o guías propuestos, va relacionada con una mejora en los resultados de la implantación del TPM; concluyéndose que el uso de estos cuestionarios en ningún momento perjudica o interfiere en el desarrollo de las metodologías de aplicación, sino que las refuerza, sirviendo de ayuda para centrar la visión y el esfuerzo de la implantación, ayudando a reforzar aspectos relevantes que dirijan su desarrollo por el buen camino. También se muestra como la potenciación de los facilitadores, y debido a su relación de jerarquías, ayuda al sostenimiento de los resultados en el tiempo, así como a reducir la necesidad de revitalizaciones periódicas del proceso de implantación del TPM. / [CAT] La present tesi doctoral aprofundeix en la dificultat que suposa l' implantació del TPM (Total Productive Maintenance), tot això per l'anàlisi de les publicacions existents: - Elabora una proposta que concreta quin és el model d'implantació del TPM més adequat i els objectius fonamentals de desenvolupament en cadascú dels passos. - Defineix una relació exhaustiva de facilitats i barreres que influeixen sobre el TPM, definint les relacions jeràrquiques que els regulen i les seves semblances amb els facilitadors propis de l' innovació contínua. - Defineix les relacions entre els conjunts facilitadors i el passos de model proposat, a través de la valoració de l'impacte que pot tindre al voltant dels seus objectius de desenvolupament i la relació amb les jerarquies existents entre tots els facilitadors. Així mateix, concreta que la dificultat que presenta d'implantació del TPM, pot reduir-se mitjançant l'ús de dos qüestionaris proposats, un d'aproximació al model d'implantació del TPM i un altre d'aproximació als facilitadors del TPM, que ajuden a suplir les carències dels models i metodologies de desenvolupament existents i serveixen com a complements que orienten al personal de planta, encarregat d'implantar el TPM, pel bon camí. Per un anàlisi longitudinal, en la present tesi doctoral es valida que els qüestionaris elaborats són els adequats i poden ser utilitzats en una empresa real, mostrant com una millora dels ítems descrits en aquestos qüestionaris o guies proposades; va relacionada amb una millora dels resultats de l' implantació del TPM; concloent que l'ús d'aquests qüestionaris en ningú moment perjudica o interfereix en el desenvolupament de les metodologies d'aplicació, sinó que les forces, serveixen d'ajuda per centrar la visió i l'esforç de l' implantació, ajudant a reforçar aspectes importants i rellevants que dirigeixen el seu desenvolupament pel bon camí. També és mostra com la potència dels facilitadors, i degut a la seva relació de jerarquies, ajuda al sosteniment dels resultats en el temps, així com a reduir la necessitat de revitalitzacions periòdiques del procés d'implantació del TPM. / Mateo Martínez, R. (2016). Propuesta y validación de un modelo integrador de implantación del Mantenimiento Productivo Total (TPM). Aplicación en una empresa industrial [Tesis doctoral no publicada]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/61492 / TESIS

La presente tesis, muestra la propuesta de mejora aplicando las metodologías del Mantenimiento Productivo Total, Kanban y la Gestión de abastecimiento de repuestos en una planta pesquera, mejorando la disponibilidad de los repuestos y reduciendo las paradas de máquina y reprocesos, con el fin de incrementar la eficiencia de la línea de producción. En el primer capítulo, se desarrolla los antecedentes de la industria pesquera, el marco teórico que describe los conceptos de las diferentes metodologías, el estado del arte con los casos de éxito, y el marco normativo. En el segundo capítulo, se realiza el diagnóstico de la situación actual de la empresa, en donde se identifica que el problema principal es la baja eficiencia de la línea de producción con un 84.86% de eficiencia media, además mediante herramientas cualitativas y cuantitativas se obtienen 8 causas raíz de tercer y cuarto nivel, sobre las cuales las metodologías escogidas tomaran acciones. En el tercer capítulo, se define el objetivo principal y los objetivos específicos alineados con las 8 causas raíz identificadas, también, se describe las etapas de la propuesta de mejora, los cronogramas, los grupos de Fiabilización, el plan maestro, indicadores y metas. Finalmente, en el cuarto capítulo, se realiza la simulación con el software Arenas, en donde se demostró que incrementando la probabilidad de stock de repuestos de 90% a 96% se obtuvo una eficiencia de 91%, y se realizó la evaluación económica en los escenarios optimista, moderado y pesimista, obteniendo indicadores a favor del proyecto. / The thesis present, shows the proposed improvement by applying the methodologies of the Total Productive Maintenance, Kanban and supply management of spare parts in a fishing plant, improving the availability of spare parts and reducing machine downtime and rework, in order to increase the efficiency of the production line. In the first chapter, the history of the fishing industry develops, the theoretical framework describing the concepts of the different methodologies, the state of the art with success stories, and the regulatory framework. In the second chapter, the diagnosis is made of the current situation of the company, where it is identified that the main problem is the low efficiency of the production line with an 84.86% average efficiency, also by qualitative and quantitative tools are obtained 8 root causes of third and fourth level, on which the methodologies chosen to take action. In the third chapter, the main objective and specific objectives aligned with the 8 root causes identified, also, the stages of the proposed improvements, schedules, groups Fiabilización, the master plan, indicators and targets described defined. Finally, in the fourth chapter, the simulation is performed with Arenas software, where it was shown that increasing the probability of stock spares from 90% to 96% efficiency of 91% was obtained, and the economic evaluation was conducted in the optimistic, moderate and pessimistic scenarios obtaining indicators for the project. / Trabajo de Suficiencia Profesional

Additive manufacturing is becoming a leading technology in the production of consumer parts. In order to compete with traditional methods which have had years to improve, additive systems must achieve a level of performance efficiency greater than it maintains today. While great effort is being expended to improve the printing time and add more systems level thinking to the problem, it is currently lacking a robust improvement methodology. To achieve the desired improvement, a technique from traditional manufacturing based on overall equipment effectiveness (OEE) is proposed. Overall additive manufacturing effectiveness (OAME) provides a methodology for enhancing this important emerging technology.

Detta examensarbete är utfört på Astrazeneca Södertälje inom Meto-försteg som är en del av fabriken API, med syftet att effektivisera underhållsarbetet. En kartläggning av det förebyggande underhållet genomfördes, i syfte att identifiera underhållsarbete som utförs dubbelt av både operatörer inom API och underhållsleverantören Caverion. Examensarbetet presenterar en redogörelse för begrepp inom underhåll, TPM (Total Productive Maintenance) och beslutsmodellen QFD (Quality Function Deployment) vilka utgör den teoretiska utgångspunkten för resultat och analys. Examensarbetet bygger på insamlade observationer och intervjumaterial från personal verksamma inom drift och underhåll. Studiens resultat visar att det genomförs överlappningar i underhållsarbetet, exempelvis inom veckotillsyn och förebyggande underhåll (FU) inom fabriksdelen Meto- försteg. Både operatörer och Caverion genomför underhållsåtgärder som innefattar visuell kontroll av oljenivåer, läckage, missljud, vibrationer för ett antal maskiner. En tydligare fördelning av underhållsåtgärder mellan operatörer och Caverion kommer bidra till effektiviseringen av underhållsarbetet. / This thesis was carried out at Astrazeneca Södertälje within Meto-pre stage, which is part of the factory API, intending to streamline the maintenance work. Apreventive maintenance survey was carried out, to identify maintenance work that was performed twice by both API operators and the maintenance provider Caverion. The thesis presents an account of concepts in maintenance, TPM (Total Productive Maintenance), and the decision model QFD (Quality Function Deployment) which constitute the theoretical starting point for results and analysis. The thesis is based on collected observations and interview materials from staff active in operations and maintenance. The results of the study show that there are overlaps in maintenance work, for example in weekly supervision/inspections and preventive maintenance (FU) within the factory part Meto-pre stage. Both operators and Caverion carry out maintenance operations that include a visual control of oil levels, leakage, noise, vibrations for several machines. A clearer distribution of maintenance measures between operators and Caverion will contribute to the streamlining of maintenance work.

Por estar diretamente sujeita a fatores econômicos de nível global, a mineração tende a se desenvolver para buscar processos produtivos mais enxutos, aliando menores custos operacionais a melhores taxas produtivas. Neste contexto, o objetivo principal deste trabalho é avaliar o comportamento geral da curva de tempo em manutenção preventiva de uma frota de caminhões em uma mineração de grande porte, sendo a análise realizada em uma janela temporal baseada em um período econômico de mínimo local nos preços do cobre. A partir do comportamento observado é feita uma discussão sob as premissas da metodologia de gestão nomeada Manutenção Produtiva Total de forma a se debater os possíveis principais riscos e/ou consequências que podem ser enfrentadas pelo projeto e como estas decisões qualitativamente indicam o grau de maturidade na integração operacional entre produção e manutenção em um projeto minerário. Ao final, pode-se concluir que ainda é necessário um intenso trabalho em se traduzir as premissas da MPT para a indústria mineral, buscando-se adaptar processos e métricas que sejam mais condizentes ao ambiente da indústria extrativa (que é muito diferente da indústria de manufatura, onde o programa teve início). Além disso, fica claro que a aplicação da MPT é possível e bem-vinda na mineração já havendo de vários estudos acadêmicos na área - ou seja, o ponto em questão mais desafiador provavelmente é que seja desenvolvido um programa de MPT de forma endógena em um projeto mineral. / As it is directly under global economic factors, the mining industry tends to develop to seek leaner production processes, combining lower operational costs to better productive rates. In this context, the main objective of this study is to evaluate the general behavior of the time spend in preventive maintenance of a truck fleet from a large-scale mining project, being the analysis performed in a time window based on an economic period of local minimum in copper prices. From the observed behavior a discussion is made under the assumptions of the management methodology named Total Productive Maintenance in order to discuss the possible main risks and/or consequences that can be faced by the project and how these decisions qualitatively indicate the degree of maturity between production and maintenance in a mining project. In the end, it can be concluded that an intense work is still needed to translate the TPM premises into the mineral industry, being necessary to seek ways to adapt processes and metrics that are more suited to the extractive industry environment (which is very different from the manufacturing industry, where the program started). In addition, it is clear that the application of TPM is possible and welcome in mining since there are several academic studies in the area - in other words, the most challenging point in question is probably that an endogenous TPM program is developed within a mineral project.

Por estar diretamente sujeita a fatores econômicos de nível global, a mineração tende a se desenvolver para buscar processos produtivos mais enxutos, aliando menores custos operacionais a melhores taxas produtivas. Neste contexto, o objetivo principal deste trabalho é avaliar o comportamento geral da curva de tempo em manutenção preventiva de uma frota de caminhões em uma mineração de grande porte, sendo a análise realizada em uma janela temporal baseada em um período econômico de mínimo local nos preços do cobre. A partir do comportamento observado é feita uma discussão sob as premissas da metodologia de gestão nomeada Manutenção Produtiva Total de forma a se debater os possíveis principais riscos e/ou consequências que podem ser enfrentadas pelo projeto e como estas decisões qualitativamente indicam o grau de maturidade na integração operacional entre produção e manutenção em um projeto minerário. Ao final, pode-se concluir que ainda é necessário um intenso trabalho em se traduzir as premissas da MPT para a indústria mineral, buscando-se adaptar processos e métricas que sejam mais condizentes ao ambiente da indústria extrativa (que é muito diferente da indústria de manufatura, onde o programa teve início). Além disso, fica claro que a aplicação da MPT é possível e bem-vinda na mineração já havendo de vários estudos acadêmicos na área - ou seja, o ponto em questão mais desafiador provavelmente é que seja desenvolvido um programa de MPT de forma endógena em um projeto mineral. / As it is directly under global economic factors, the mining industry tends to develop to seek leaner production processes, combining lower operational costs to better productive rates. In this context, the main objective of this study is to evaluate the general behavior of the time spend in preventive maintenance of a truck fleet from a large-scale mining project, being the analysis performed in a time window based on an economic period of local minimum in copper prices. From the observed behavior a discussion is made under the assumptions of the management methodology named Total Productive Maintenance in order to discuss the possible main risks and/or consequences that can be faced by the project and how these decisions qualitatively indicate the degree of maturity between production and maintenance in a mining project. In the end, it can be concluded that an intense work is still needed to translate the TPM premises into the mineral industry, being necessary to seek ways to adapt processes and metrics that are more suited to the extractive industry environment (which is very different from the manufacturing industry, where the program started). In addition, it is clear that the application of TPM is possible and welcome in mining since there are several academic studies in the area - in other words, the most challenging point in question is probably that an endogenous TPM program is developed within a mineral project.

Orientador: Antonio Cesar Germano Martins / Resumo: Buscar alternativas ao que usualmente é feito diariamente nas empresas, possibilita construir uma visão diferenciada de processos e atitudes, que permite propor um conjunto de ações para se obter resultados diferentes dos observados até então. Neste contexto encontra-se a utilização do pilar de Manutenção Autônoma (MA) da ferramenta de Manutenção Produtiva Total (TPM), sendo proposto nesta tese, sua utilização com um novo propósito, inovador, o de mitigar a geração de resíduos. Usualmente o pilar é utilizado para envolver os diversos atores dos processos produtivos na conservação dos equipamentos, com o objetivo de melhorar seu desempenho, reduzindo falhas não previstas ou aumentando a disponibilidade e confiabilidade. Em um cenário composto prioritariamente por micro e pequenas empresas produtoras de calçados femininos, instaladas em um Arranjo Produtivo Local (APL) no município de Jaú/SP, encontrou-se um cenário com possibilidades de se alterar o ambiente de trabalho com estas ações inéditas. Explorando um cenário que usualmente não utiliza ferramentas de manutenção, tal como a TPM, para introduzir a nova proposta, visando reduzir a geração de resíduos perigosos originados no processo produtivo. Assim, a proposta aqui, foi utilizar de forma inovadora a MA da TPM, aplicada ao setor de corte manual de uma empresa produtora de calçados femininos, instalada no APL de Calçados Femininos de Jaú/SP, com o objetivo de obter os mesmos resultados no tocante à redução dos resíduos dos... (Resumo completo, clicar acesso eletrônico abaixo) / Doutor