This work focuses on the issues related to improving the manufacturing process effectiveness in the company Boltjes International spol. s r.o, based on the principles of lean manufacturing. It mainly comes out from the theoretical principles of the Toyota Production System. Based on the analysis of the organisation of the manufacturing system of the company Boltjes the graduation theses describes problematic areas. The paper establishes their priorities and submits practical proposals and recommended solutions in the direction of higher productivity of the complete manufacturing process. The paper uses for these solutions a method of a qualified significance tree and the mapping of the manufacturing flows. The paper deals with stock management, organisation of the manufacturing system and with management of human resources.

"Starting in the 1980s with the first Toyota controlled production plant in the United States (NUMMI), the idea of Lean as derived from the Toyota Production System has become a popular method to improve production processes as well as any other procedure in organizations around the world. Over the last three decades a multitude of literature on Lean implementation and consulting companies offering help with the Lean transformation have emerged. The success rate of real Lean transformations however is often estimated to lie below 10% by experts such as Clifford Ransom or members of the Society of Manufacturing Engineers (SME). This leads to the question of why most companies fail to sustain the Lean improvements that most of them are able to initiate during the early implementation stages. This thesis will therefore investigate the root causes that lead to a time dependent loss of Lean improvements from three different perspectives. One standpoint is given by the TPS beliefs which are united in the House of Lean. The second angle on the topic is drawn from an online search of expert opinions and the final evaluation is taken from analyzing a real case scenario at a plant in Trumbull, CT. After this thorough analysis of possible root causes a set of countermeasures is presented that will support an organization in avoiding the major mistakes of a Lean implementation. The three countermeasures include standardization to build a base for Lean improvements, employee involvement to assure sustainability through conviction and continuous instead of rapid improvement. Every countermeasure will be described theoretically as well as with the help of examples from real life scenarios to enable the reader to apply the suggestions immediately. A final discussion will then examine the improvements that where reached at the production plant in Trumbull, CT and show how the combination of all three countermeasures ensures the sustainability of these improvements."

Organizations around the world have attempted to implement the concepts of the Toyota Production System (TPS), commonly referred to as Lean, with limited sustainable success. The central principles of TPS, continuous improvement and respect for people, are grounded in the Japanese values of Monozukuri and Hitozukuri. Monozukuri deals with creating or making a product, while Hitozukuri conveys the idea of developing people through learning. In order for organizations to adopt these values they must have a system that engages employees at all levels in applying problem solving to improve their work. This research uses organizational assessments obtained from a variety of organizations implementing the lean approach using the Monozukuri and Hitozukuri values, referred to as the True Lean System (TLS). This research uses an inductive research approach to identify and analyze factors that impact the use of problem solving within organizations implementing a TLS. First, the qualitative assessment data is studied using textual analysis to identify themes impacting TLS. This analysis identified three topics as the highest weighted themes: number of problem solving methods, standardization, and employee roles. This qualitative data is then transformed using an integrated design model to systematically code the information into quantitative numerical data. Finally, this data was analyzed statistically by logistic regression to identify the factors impacting the use of problem solving within these organizations. The results from the logistic regression suggest that the most successful problem solving organizations have established standards for work and training employees; as well as, a single problem solving method that all employees use when identifying and implementing continuous improvement ideas. Which leads to the conclusion, in order for an organization to sustain the concepts of TPS, there must be a focus on defining clear standardized work, training, and the implementation of a single problem solving method.

<p>Detta examensarbete har utförts vid Elitfönster AB i Vetlanda. Elitfönster AB är Sveriges största leverantör av fönster och fönsterdörrar.</p><p>Syftet med arbetet är att ta fram åtgärdsförslag för att minska ledtiderna, då korta leveranstider blir ett allt viktigare konkurrensmedel. Arbetet innebar en kartläggning av nuvarande produktionsflöde och identifiering av problemområden.</p><p>Arbetet genomfördes med hjälp av tidsstudier och intervjuer med arbetsledare och personal. Arbetet bygger även en hel del på observationer, iakttagelser och studerande av statistik.</p><p>I stora drag kan man dra slutsatsen att de långa ledtiderna beror på främst två orsaker;</p><p>• hyvelbanornas långa ställtider som medför körningar i veckosatser</p><p>• kvalitetsbrister och bristfälliga kvalitetskontroller samt trästycken som ”försvinner” längs förädlingskedjan. Detta leder till att order får ställas åt sidan i väntan på nya/omlackade bitar.</p><p>För att erhålla en reducering av produktionsledtiden bör Elitfönster AB i första hand;</p><p>• överväga att flytta ut ett eller två produktsortiment, vilket skulle medföra reducerade ställtider i hyvelbanorna och därmed en möjlighet att bryta ner veckosatserna i mindre satser.</p><p>• sträva mot att synkronisera de olika resursernas cykeltider mot takttiden.</p><p>• skapa stabila processer, det vill säga tillförlitlig utrustning och mångkunnig personal, för att kunna minimera buffertar och mellanlager.</p><p>• kontinuerligt kvalitetsarbete i form av leverantörssamverkan och kvalitetsutbildningar till personal.</p>

Detta examensarbete har utförts vid Elitfönster AB i Vetlanda. Elitfönster AB är Sveriges största leverantör av fönster och fönsterdörrar. Syftet med arbetet är att ta fram åtgärdsförslag för att minska ledtiderna, då korta leveranstider blir ett allt viktigare konkurrensmedel. Arbetet innebar en kartläggning av nuvarande produktionsflöde och identifiering av problemområden. Arbetet genomfördes med hjälp av tidsstudier och intervjuer med arbetsledare och personal. Arbetet bygger även en hel del på observationer, iakttagelser och studerande av statistik. I stora drag kan man dra slutsatsen att de långa ledtiderna beror på främst två orsaker; • hyvelbanornas långa ställtider som medför körningar i veckosatser • kvalitetsbrister och bristfälliga kvalitetskontroller samt trästycken som ”försvinner” längs förädlingskedjan. Detta leder till att order får ställas åt sidan i väntan på nya/omlackade bitar. För att erhålla en reducering av produktionsledtiden bör Elitfönster AB i första hand; • överväga att flytta ut ett eller två produktsortiment, vilket skulle medföra reducerade ställtider i hyvelbanorna och därmed en möjlighet att bryta ner veckosatserna i mindre satser. • sträva mot att synkronisera de olika resursernas cykeltider mot takttiden. • skapa stabila processer, det vill säga tillförlitlig utrustning och mångkunnig personal, för att kunna minimera buffertar och mellanlager. • kontinuerligt kvalitetsarbete i form av leverantörssamverkan och kvalitetsutbildningar till personal.

Abstract The company for case study always dedicates to reinforce interior constitution as well as exterior competition, the major core is surrounding The Toyota Way, which it started with ¡§SEIRI and SEITON¡¨, ¡§Streamline Production¡¨ to ¡§Toyota Production System, TPS¡¨ from manufacturing fields, and then the company mind of ¡¨The Toyota Way¡¨. The development of each phase has its strategic position with different gradation. Moreover, in order to incorporate the operation for both Taiwan headquarter and China facility, divisions are segmented by operational functions for appropriate redeployment and valued-connection. The core for developing this study have had the case company to implement ¡§The Toyota Way, through meticulous discussions in order to clarify the built-up of ¡¨The Toyota Way¡¨ in the case company. First, start from ¡§manufacturing perspective¡¨ from working fields, with Streamline Production and Just-In-Time production as basic capabilities to build up the strength. Furthermore, extend it to the system of ¡¨ Product Developing Process Management¡¨, and connect with Big-Room ¡§Obeya¡¨ activity, ¡§Preparation prior to mass production¡¨, ¡§Supplier Parts Tracking Team, SPTT¡¨, and ¡§Cost Management¡¨¡C Last, through the strategic plan of company operation and functions of TPS operation with Knowledge of Philosophy from System, Method and Nature, to develop a series of deep competitions for the strength of company enhancement. Summarizations above, conclusions of the research are as following- 1. Generalized each activity and operating function with four perspectives as Company Philosophy, Elimination of Waste, Business Partners and Continuous Improvement, while the case company implemented TPS. Furthermore, described what the case company¡¦s functions of implement or concepts of application, which expect the study could be referred while related corporations try to implement them in the future. 2. Beside fully support from executive management to carry out the philosophy of The Toyota Way into organizational operation¡¦s thinking in the corporation, the most critical key-point is that it is necessary to create an environment with continuous improvement and participation of all employees in order to seed the realization into everyone¡¦s mind deeply.

Diversity of consumers, timely needs of the times, combined with market information, production and selling out of products, enterprises can profit possible. Want in the fierce competition; we must attach importance to production and sales co-ordination and integration. This study aimed to clarify the "Toyota production and sales integrated management system," in close connection with production and sales, rapid response to changes in the meaning and operation of the structure and conditions of its formation. "Toyota production and sales integrated management system," the biggest feature is the production site with frequent sales information for the various stages of the production plan to do a different range of amendments, the final production and micro-adjustments to billboards, fast response to changes in demand. In the full sales pipeline, the distributor effective master customer information and establish long-term relationships with customers, thus the right to collect and prepare sales forecasts, and quickly back to the Toyota Motor Sales, such as Toyota's strong sales management an important support system behind the production factors. "Toyota production and sales integrated management systems," the transfer of applications across industries, from brand computer makers and electronics contract manufacturing service provider of supply chain production micro-tune the system for evidence. Through analysis and comparison of the two operational framework that, dismantling of production steps, multi-stage production scheduling amendments, the changes in the components remain the highest to the final assembly, so that the flexible "instant production of Just-In-Time" , can be applied in different industries. "Toyota production and sales integrated management systems," the production of micro-adjustment of the operational structure to clarify and resolve inter-industry transfer of instances, not only academic significance, other electronic products manufacturing industry for practical application, also has a reference value.

The nature of range ¡§ automobile ¡§ has high technology and traditional science both together. It expands living habit and areas for the human beings but also lead hazard and risky on environment and safety. What is the value of competition about the automobile? What are the cons and pros on traditional manufactures with United States, Japan and Germany? Any structure change from then until now? The subject essay is based upon the automobile research report, which was issued on 1990 by MIT, analysis of GM with The United States, Toyota with Japan and Volkswagen with the Germany 1991-2005 financial statements and volume production strategy to continue the analysis. The automobile manufactures were following the model of productions TPS after MIT research report was announced. The above companies were not being able to follow and copy the model very successfully. Because that past successful enterprise cultural was difficult to abandon and among different countries cultural background and basis were total different and individual. They could only practice the fur of Japanese Toyota. For example, GM was combined with Toyota to build up factory as issue; looks like GM have had good flow and function on inventory turn over percentage and cost of sales volume. After operation factors were getting worse even turn their inefficiency out to the fact. The traditional craftsman¡¦s art with Germany were become the sign of obstacle to the TPS.

Denna studie är utförd på ett företag i Helsingborg som heter Abdon Finax AB. Företaget startade med mjöltillverkning för att sedan introducera müslin till Sverige. Sedan dess har bolaget fortsatt växa. I dagens samhälle går utvecklingen fort fram. Globaliseringen innebär att konkurrensen ökar och företag tvingas att tävla med varandra om kunderna, vilka ständigt söker bättre kvalitet, lägre kostnader samt kortare ledtider. Detta samtidigt som företagen försöker tjäna mer pengar genom ökad lönsamhet genom bland annat effektivare flöden. På så sätt kan företaget minimera kostnaderna för att kunderna ska kunna tillgodoses samtidigt som företagen tjänar på det. ’’Ibland måste man vara liten för att springa om de stora’’ är ett av Finax valspråk. För att fortsätta ha chansen att springa om de stora krävs flexibilitet i produktionen för att möjliggöra kortare ledtider till kunderna. Syftet med studien har varit att analysera flödet av de glutenfria produkterna på Abdon Finax AB för att finna effektiviseringsområden. För att kunna göra detta har en flödeskartläggning gjorts. Denna gjordes med hjälp av observationer samt intervjuer på företaget. Efter en jämförelse mellan teori och empiri har sedan några kritiska punkter pekats ut för förbättring och effektiviseringsförslag har rekommenderats. Dessa förslag involverar standardisering samt sänkningsförslag på omställningstiderna allt för att företaget ska öka sin flexibilitet och kunna producera i mindre batcher. Vilket ska leda till att ledtiderna minskar och även lagerkostnaderna. I framtiden när ställtiderna har minimerats skulle det vara fullt möjligt att producera efter kundorder vilket minimerar riskerna för att kassera produkter samt minskar lagerkostnaderna ytterligare.

Lean Manufacturing (LM) is widely accepted as a world-class manufacturing paradigm, its currency and superiority are manifested in numerous recent success stories. Most lean tools including Just-in-Time (JIT) were designed for repetitive serial production systems. This resulted in a substantial stream of research which dismissed a priori the suitability of LM for non-repetitive non-serial job-shops. The extension of LM into non-repetitive production systems is opposed on the basis of the sheer complexity of applying JIT pull production control in non-repetitive systems fabricating a high variety of products. However, the application of LM in job-shops is not unexplored. Studies proposing the extension of leanness into non-repetitive production systems have promoted the modification of pull control mechanisms or reconfiguration of job-shops into cellular manufacturing systems. This thesis sought to address the shortcomings of the aforementioned approaches. The contribution of this thesis to knowledge in the field of production and operations management is threefold: Firstly, a Multi-Agent System (MAS) is designed to directly apply pull production control to a good approximation of a real-life job-shop. The scale and complexity of the developed MAS prove that the application of pull production control in non-repetitive manufacturing systems is challenging, perplex and laborious. Secondly, the thesis examines three pull production control mechanisms namely, Kanban, Base Stock and Constant Work-in-Process (CONWIP) which it enhances so as to prevent system deadlocks, an issue largely unaddressed in the relevant literature. Having successfully tested the transferability of pull production control to non-repetitive manufacturing, the third contribution of this thesis is that it uses experimental and empirical data to examine the impact of pull production control on job-shop performance. The thesis identifies issues resulting from the application of pull control in job-shops which have implications for industry practice and concludes by outlining further research that can be undertaken in this direction.