The purpose of this thesis is to develop a model for assessing cost effectiveness of applying lean tools. The model consists of eight phases: it starts by understanding customers' requirements using Voice of Customer (VOC) and Quality Function Deployment (QFD) tools. In phase 2, the current state of plant is assessed using lean profile charts based on Balanced Scorecard (BSC) measures. In phase 3 and phase 4, identification of critical problem(s) and generating of improvement suggestion(s) are performed. Phase 5 provide evaluation of the cost effectiveness of implementing the suggested lean methods based on life cycle cost analysis (LCCA) and phase 6 prefers the right alternative based on multiple criteria decision making (MCDM). In phase 7 the selected alternative is supposed to be implemented and finally the user should monitor and control the process to make sure that the improvement is going as planned. The model was verified successfully using a case study methodology at one Swedish sawmill called Södra Timber in Ramkvilla, one part of Södra group. Results obtained from the study showed that the production and human resources perspectives are the most critical problem areas that need to be improved. They got the lowest scores in the lean profile, 63% and 68%, respectively. Using value stream mapping (VSM) it was found that the non value added (NVA) ratios for the core and side products are 87.4% and 90.4%, respectively. Using the model, three improvement alternatives were suggested and evaluated using LCCA and MCDM. Consequently, implementing 5S got the highest score, second came redesigning the facility layout. However, it was estimated that 4.7 % of NVA for the side product would be reduced by redesigning the facility layout. The recommendations were suggested for the company to improve their performance. The novelty of the thesis is based on the fact that it addresses two main issues related to lean manufacturing: firstly, suggesting lean techniques based on assessment of lean profile that is based on BSC and QFD, and secondly assessing the cost effectiveness of the suggested lean methods based on LCCA and MCDM. This thesis provides a generalized model that enables the decision-maker to know and measure, holistically, the company performance with respect to customer requirements. This will enable the company to analyze the critical problems, suggest solutions, evaluate them and make a cost effective decision. Thus, the company can improve its competitiveness.

<p>The purpose of this thesis is to develop a model for assessing cost effectiveness of applying lean tools. The model consists of eight phases: it starts by understanding customers' requirements using Voice of Customer (VOC) and Quality Function Deployment (QFD) tools. In phase 2, the current state of plant is assessed using lean profile charts based on Balanced Scorecard (BSC) measures. In phase 3 and phase 4, identification of critical problem(s) and generating of improvement suggestion(s) are performed. Phase 5 provide evaluation of the cost effectiveness of implementing the suggested lean methods based on life cycle cost analysis (LCCA) and phase 6 prefers the right alternative based on multiple criteria decision making (MCDM). In phase 7 the selected alternative is supposed to be implemented and finally the user should monitor and control the process to make sure that the improvement is going as planned. The model was verified successfully using a case study methodology at one Swedish sawmill called Södra Timber in Ramkvilla, one part of Södra group. Results obtained from the study showed that the production and human resources perspectives are the most critical problem areas that need to be improved. They got the lowest scores in the lean profile, 63% and 68%, respectively. Using value stream mapping (VSM) it was found that the non value added (NVA) ratios for the core and side products are 87.4% and 90.4%, respectively. Using the model, three improvement alternatives were suggested and evaluated using LCCA and MCDM. Consequently, implementing 5S got the highest score, second came redesigning the facility layout. However, it was estimated that 4.7 % of NVA for the side product would be reduced by redesigning the facility layout. The recommendations were suggested for the company to improve their performance. The novelty of the thesis is based on the fact that it addresses two main issues related to lean manufacturing: firstly, suggesting lean techniques based on assessment of lean profile that is based on BSC and QFD, and secondly assessing the cost effectiveness of the suggested lean methods based on LCCA and MCDM. This thesis provides a generalized model that enables the decision-maker to know and measure, holistically, the company performance with respect to customer requirements. This will enable the company to analyze the critical problems, suggest solutions, evaluate them and make a cost effective decision. Thus, the company can improve its competitiveness.</p>

Cocoa has been useful in several ways, especially to countries that produce it and consumers all over the world. Its benefits range from improving economies to satisfying millions all over the world who desire one cocoa product or the other. The production of cocoa however is not without its own attendant problems. Aging tree stock, spread of diseases, and production capacity problems are, but a few of many challenges that seed gardens that produce cocoa face. This study investigated the pollination process on selected seed gardens in Ghana, the second largest world producer of cocoa. The purpose of this study was to investigate the artificial pollination process of cocoa on seed gardens in Ghana, and explore ways by which the Lean principle of Value Stream Mapping could be applied in improving the process. The process of pollination was observed on eighteen seed gardens, and a current value stream map depicting the existing process developed to give an indication of the current state of affairs. Subsequently, a future value stream map based on the current map was developed to show aspects of the process that could be improved to enhance the operations of the seed gardens. The future value stream map revealed that operational procedures relating to cleaning and preparation of trees, choosing male and female trees for pollination, harvesting of pollen, and manually pollinating practices presented various avenues for improving the pollination process and hence seed production output.

Saab Component Maintenance in Linköping, Sweden, offers maintenance, repair and overhaul (MRO) services for civilian and military aircraft components. Lately, the department has struggled with slow throughput rates, despite various counteracting attempts. Studies show, that large parts of the delays derive from the logistics department where goods arrive and dispatch. Therefore, Saab wants to carry out an extensive analysis of the department in order to further investigate what is causing its slow throughput rates. The thesis begins with extensive mapping over Component Maintenances whole value stream to find out how departments interact with each other and which role individual departments have in the total supply chain. Out of 13 000 different part numbers, components were divided into five product families. From statistical history of package frequency, two value streams were chosen as scientific research objects, where improvements of which show great potential to have serious positive effects. From activity studies, observations, workshops and interviews various elements were identified as obstructing in the logistics department’s material and information flow. Activity studies show, that 55, 8% of activities performed in the arriving goods department were considered as value adding time. In addition, 67, 9% of activities performed in the dispatch goods department were considered as value adding time (where over half of the value adding time was spent in administrative systems). 11 critical challenges and five associated root causes have been identified in the arriving goods department. 14 critical challenges and five associated root causes have been identified in the dispatch goods department. To reduce and prevent further waste, the thesis recommends 14 critical actions in order to reduce the amount of elements obstructing the flow of material and information at Component Maintenance. In addition, recommended changes have been illustrated in a Future State Map for each department respectively on a process level. By performing tasks in new sequences where material and information flow progresses in a parallel synchronized rate, the benefits of a balanced lean flow could be demonstrated in the dispatch department. Shortest lead time, from finished component to packaged and booked shipment, was noted for small units and took 20 minutes.

Bakgrund: I sjukhusets unika miljö kan vikten av effektiva flöden ha avgörande betydelse för liv eller död. Förutsättningarna för logistiken i ett sjukhus är föränderlig och för att hänga med i olika förbättringstekniker måste sjukhusen utvecklas. Lösningen kan vara lean i sjukvård, men forskningen inom området är begränsad, vilket ger upphov till fortsatta studier inom ämnet.   Syfte: Studien syftar till att ge utökad kunskap om lean genom att ta reda på utmaningar för samordning av två varuförsörjningsflöden samt identifiera faktorer för effektiv varuförsörjning inom sjukvården. Metod: För att besvara syftet och forskningsfrågorna har en abduktiv ansats använts, där litteraturen inhämtats parallellt med empirisk data från en fallstudie på Gävle sjukhus. Teori från litteraturen och resultatet från fallstudien har analyserats, diskuterats och utifrån analysen har en slutsats utarbetats. Resultat: Studiens resultat är en värdeflödesanalys av processen för den interna varuförsörjningen av förbrukningsartiklar på Gävle sjukhus. Genom kartläggningen åskådliggörs slöserier som de separata flödena ger upphov till.     Begränsningar: Området för lean och logistik i sjukvård är delvis outforskat och området är i behov av utvecklad kunskap. Då sjukhusets avdelningar tycks ha olika hantering för den interna varuförsörjningen hade ett utökat antal inkluderade informanter varit gynnsamt för studien. Implikationer: Studien utökar kunskapen för ämnet genom att identifiera utmaningar med arbetskulturen samt svårigheter i att standardisera processer och eliminera slöserier. Studien identifierar därtill informationsflöde, systemstöd och värdeflödesanalys som betydelsefulla faktorer för effektiv varuförsörjning på ett sjukhus. Dessutom definieras ett uttryck för logistiken i sjukhus – sjukhuslogistik. / Background: In the unique environment of a hospital the importance of efficient logistics can be a matter of life and death. The conditions for the logistics in a hospital are constantly changing and to keep up with progress being made in different techniques of improvement hospitals must evolve. The answer could be lean healthcare but the research in this area is limited and thus more studies are required. Purpose: This study aims to broaden the knowledge about lean healthcare, through exploring the challenges involved with coordination of supply flows and also by identifying success factors of efficient supply flows. Method: To answer the purpose and the research questions the study utilizes an abductive approach where the literature has been acquired in parallel with the empirical data from a case study made on Gävle hospital. Both theoretical and empirical data has then been analyzed and through this analysis a conclusion has been formed. Findings: The study is made by a value stream mapping of the internal supply chain of consumable goods at Gävle hospital. Through the mapping numerous areas of waste can be identified, which is the result of having separate supply chains. Limitations: More research in the area of using lean and logistics in combination with healthcare are still needed. Since management of the internal supply chain varies at the different hospital departments an increased number of informants would have been favorable for the study. Implications: This paper explores the topic by identifying challenges within the work culture, difficulties with standardization of processes and eliminating waste. The study also identifies flow of information, system support and value stream mapping as success factors for an efficient internal supply chain within a hospital. Because there is a lack of vocabulary for describing the area of healthcare logistics in the Swedish Language, a definition for this is also contributed in the study.

The movement and handling of material are necessary activities, however, commonly regarded as waste. Moving and handling material more times and over longer distance than necessary is time consuming, costly and unproductive. Therefore, a suitable material handling (MH) system with appropriate facility layout is advocated. The purpose of this thesis is to explore options for material flow improvements and handling of material in production area. This comprises of a study of the material flow from storage to production areas and the handling of material in production section A. If necessary for improvements of material flow, a change in layout design will be recommended. The research approach for this thesis is a case study where data has been collected from documents, observations and interviews. The study shows that 9 % of the production time of one article is spent on manual material handling (MMH). These activities are classified as both waste and necessary, however not adding any value. The same applies for the material flow. Unnecessary distances of movements are caused by the current location of storage, operations and lack of proper structure for handling and moving material. The contribution of this study is a list of suggestions for improving the material flow and handling. Changes for improvements are, namely, availability of appropriate equipment, storing materials closer to the operations and investing in automation and vision systems with cameras of robots. The material flow and the way the material is handled can further beimproved by a change in the layout of the production area. Connecting and rearranging operations can shorter and ease the movement of material with ample space to handle the material.

Till följd av ökande krav från kunder blir dagens konkurrenssituation på marknaden allt hårdare för företag. Dessa krav bidrar till att företagen måste satsa på ökad effektivitet och långsiktig lönsamhet. Lean är ett känt begrepp inom industrin som vid implementering syftar till att reducerar eller eliminera slöseri i informations- och materialflöden vilket leder till effektivisering. Denna studie bygger på ett problem som existerar i ett flertal informations- och materialflöden i en processindustri. Fallföretaget i denna studie är Iggesund Paperboard som önskar klarhet angående flödena samt minskade ledtider och lagernivåer. Syftet med studien är att undersöka hur internt materialflöde samt beställning och prognostisering av material kan effektiviseras för att reducera ledtid och lagernivåer. Studien utfördes genom en fallstudie där datainsamling på fallföretaget samlades in genom intervjuer, observationer och dokumentstudier. Parallellt samlades information också in genom litteratur. Datainsamlingen utgjorde sedan underlag till analys och slutsatser för denna studie. Resultatet i form av kartläggningen av informations- och materialflöden visar på ett komplext flöde med många aktiviteter som bidrar till slöseri. Orsakerna till slöseri i flödena är varierande och bidrar till ökade ledtider och lagernivåer. Vid kartläggningen utformades två bilder med två värdeflöden i varje bild som tillsammans med förbättringsförslag kan skapa kontroll och minska ledtider och lagernivåer. Det vetenskapliga bidrag som denna studie frambringar är att utöka kunskapen inom dokumentering och analysering, samt tillämpning av lösningar baserade på filosofin inom Lean, för administrativa arbetsuppgifter. Bidraget är således att kombinera och utföra samma tillämpning på ett informations- och materialflöde i helhet och inte var för sig. Förslag till vidare forskning är att utföra undersökningen som gjort i studien under en längre tidsperiod samt i fler miljöer för att ge prov på ökad trovärdighet. / Companies meet tougher competition at the marketplace as a consequence of increasing customer demand. As a result they have to focus on increasing their efficiency and look for long-term profitability. Lean is a known concept within the world of industries that aims to reduces or eliminates waste in information- and material flows which will lead to effectiveness. The findings of his study are based on a problem within a process industry. The problem comprises information- and material flows where the company Iggesund Paper requests clarity in the flows, and reduced lead time and stock levels. The purpose with this study is to investigate how internal material flow, forecasting orders and ordering materials can be developed to be more efficient and reduce lead-time and stock levels. This study is carried out as a case-study where the data was collected through interviews, observations, document studies and literature review. The data collection gave a solid ground for further analysis and conclusions. The value stream mapping and the description of the information- and material flows indicates and identifies complexity and activities contributing to waste. This situation leads to increasing lead-times and stock levels. The cause of the situation is varied but with the maps of the flows and the improvement proposals improvements can be made and effectiveness can be achieved. The theoretical contribution of this study is to extend research and considering applying tools within the Lean philosophy on administrative work, and together with the same application on work with material flow this study combine the proposals of improvements for the entire process. Suggestions for further research are to extend the time of the field study and likewise apply the methods of the study in additional situations to extend the validity and reliability.

Submitted by Bruna Rodrigues (bruna92rodrigues@yahoo.com.br) on 2016-09-30T14:08:13Z No. of bitstreams: 1 DissISMR.pdf: 5225633 bytes, checksum: 3964aaa110c5fcc9937a9703d753f179 (MD5) / Approved for entry into archive by Marina Freitas (marinapf@ufscar.br) on 2016-10-04T18:50:45Z (GMT) No. of bitstreams: 1 DissISMR.pdf: 5225633 bytes, checksum: 3964aaa110c5fcc9937a9703d753f179 (MD5) / Approved for entry into archive by Marina Freitas (marinapf@ufscar.br) on 2016-10-04T18:50:51Z (GMT) No. of bitstreams: 1 DissISMR.pdf: 5225633 bytes, checksum: 3964aaa110c5fcc9937a9703d753f179 (MD5) / Made available in DSpace on 2016-10-04T18:50:56Z (GMT). No. of bitstreams: 1 DissISMR.pdf: 5225633 bytes, checksum: 3964aaa110c5fcc9937a9703d753f179 (MD5) Previous issue date: 2015-08-25 / Não recebi financiamento / In the current globalized world, the market is characterized by the high competitiveness, easy access to information and high consumer demand. The analysis of the impacts of lean office application to the supply unit on a construction company is very relevant, considering that companies focused on the civil construction area depend for consolidation of their businesses, efficient management strategies and suppliers of materials and services, external to their organization. The use of lean office as a management tool in the purchasing department of construction companies offers a competitive advantage amid the current market situation. Thereby, this study seeks to clearly conceptualize the lean philosophy and its tools as well as the management of the information systems and also the management of the supply chain, among other aspects. One construction company was then selected for the design research. This company contributes with information for the accomplishment of this work. The method used in this dissertation consists in describing the company, drawing the preliminary map of the supply unit, from this, it was possible to draw up the value stream map in the present state. With this map it could be analyzed and proposing improvements in the production process and then, designed a value stream map in the future state, applying these enhancements. The results led to the identification of flaws and possible opportunities for management improvements in the company. / No atual contexto globalizado o mercado é caracterizado pela alta competitividade, fácil acesso às informações e elevada exigência do consumidor. A análise dos impactos da aplicação do lean office na unidade de suprimentos de uma construtora, é de alta relevância, visto que empresas voltadas à área da construção civil dependem, para consolidação dos seus empreendimentos, de estratégias de gestão eficientes e de fornecedores de materiais e serviços externos à sua organização. Sendo assim, a utilização do lean office, como ferramenta gerencial na unidade de compras, oferece às empresas construtoras uma vantagem competitiva em meio à presente situação do mercado. O presente trabalho procurou conceituar a filosofia enxuta e suas ferramentas, o gerenciamento dos sistemas de informação e a gestão do setor de suprimentos, entre outros aspectos. A partir destes, buscou-se uma empresa construtora para realizar uma pesquisa-ação. Esta construtora contribuiu com informações necessárias para realizar esta dissertação. O método utilizado nesta dissertação consiste em descrever a empresa, desenhar o mapa preliminar da unidade de suprimentos e a partir deste elaborar o mapa de fluxo de valor presente para a unidade, analisando-o e propondo melhorias em seu processo de produção. Em seguida criar um mapa de fluxo de valor no estado futuro, aplicando estes aprimoramentos. Os resultados levaram à identificação das falhas e das possíveis oportunidades de melhorias de gestão na empresa estudada.

Made available in DSpace on 2015-05-08T14:53:31Z (GMT). No. of bitstreams: 1 arquivototal.pdf: 2225329 bytes, checksum: aeb2b58ce9683163296978cd44822c1c (MD5) Previous issue date: 2012-08-30 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / This dissertation concerns the application of the Activity Based Costing method (ABC) as a tool to hold cost reduction in service companies. The first step was the contextualization of the method importance followed by the justification of the research. After that, a literary review was made and it involved value chain, cost management, ABC method, time-driven ABC, target costing, kaizen costing, value stream mapping and tourism. Based on the researched literature this survey could be separated in three phases: (1) application of the costing method in service costing, (2) application of the value stream mapping in services with a greater incidence of indirect costs and (3) suggestion of a more appropriated cost reduction technique to the service in analysis. This research is exploratory and applied; it is also focused on three case studies in service, two restaurants and a travel agency. The results obtained with the survey indicate service costs and point out the ABC method as an auxiliary tool in the search for cost reduction, having in mind that the more accurate treatment of indirect costs provided by ABC method facilitated the identification of the services which needed wastage analysis. In the last chapter the final considerations related to the research are presented as well as suggestions for future searches. / Esta dissertação trata da aplicação do método de custeio ABC (Activity Based Costs) como ferramenta de suporte à redução de custos em empresas no setor de serviços. Primeiramente, contextualizou-se a importância do método e justificou-se a realização da pesquisa. Em uma etapa posterior realizou-se uma revisão de literatura sobre cadeia de valor, gestão de custos, método de custeio ABC, time-driven ABC, custeio-meta, custeio kaizen, mapeamento do fluxo de valor, finalizando com uma breve revisão no setor de serviços com ênfase na atividade turística. Baseado na literatura pesquisada dividiu-se este estudo de caso em três fases: (1) Aplicação do método de custeio ABC em três empresas do setor serviços, (2) Aplicação do mapeamento do fluxo de valor nos serviços com maiores incidências de custos indiretos e (3) sugestão de técnica de redução de custos mais apropriada para o serviço em análise. A pesquisa possui natureza exploratória e aplicada, focada em um estudo de três casos no setor de serviços, dois restaurantes e uma agência de viagens. Os resultados obtidos na pesquisa indicam os custos dos serviços prestados e aponta o ABC como uma ferramenta auxiliar na busca pela redução de custos, pois o tratamento mais acurado dos custos indiretos fornecido pelo ABC facilitou a identificação dos serviços que necessitavam de uma análise nos desperdícios. No último capítulo são apresentadas as considerações finais acerca da pesquisa e sugestões de pesquisas futuras.

Orientador: Paulo Correa Lima / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-07T04:02:28Z (GMT). No. of bitstreams: 1 Calado_RobisomDamasceno_M.pdf: 2515663 bytes, checksum: 21c4fbba4a8cbe4ea49b31b3b7a19b49 (MD5) Previous issue date: 2006 / Resumo: A competitividade em mercados globalizados, bem como a inovação e difusão de novas técnicas e métodos, oriundas do Sistema Toyota de Produção e Controle de Qualidade Total, são aplicadas em fábricas de todo o mundo e tem alavancado constante melhoria nos postos de trabalho e considerável redução dos riscos de acidente, pois a segurança está no escopo da melhoria de produtividade e qualidade. Neste trabalho foca-se a eliminação do risco de acidente (problemática específica do objeto de estudo) através da aplicação dos conceitos e ferramentas da manufatura enxuta, como mapeamento do fluxo de valor e célula de manufatura, de forma integrada ao objeto de estudo e seus trabalhadores com uso da metodologia de pesquisa-ação, desta forma foi possível obter resultados qualitativos e aumento da produtividade no processo de injeção e tampografia de peças plásticas, este trabalho pode servir de motivação e fonte de pesquisa para se implementar melhorias nas inúmeras empresas do ramo plástico entre outros segmentos de manufatura de bens de consumo / Abstract: The competitiveness in global markets, as well as the innovation and diffusion of new techniques and methods, original from Toyota Production System and Total Quality Control, are applied in factories worldwide and have provided continuous improvement in workstations and a deep reduction of accident risks, because larger safety is the target of productivity improvement and quality. In this paper focused the elimination of the accident risk (specific problem of the object of study) through the application of the concepts and tools of Lean manufacturing, as Value Stream Mapping and Manufacture Cell, on way integrated the study object and their workers with use of research-action methodology, have been able to obtain qualitative results that can be useful as motivation and research sources for improvements implementation in many companies of plastic activity among other segments of consumption goods production / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica