This dissertation reports the investigation and combination of optimization methodologies and the result of implementing them within a production environment. A literature survey was conducted on the optimization methodologies Lean Manufacturing and theory of constraints (TOC). A number of production optimization methodologies were studied and considered for application to the case study organisation. Due to the small size and relative simplicity of the operation, these methodologies had to be simplified and combined into a more relevant form. A refractory manufacturer was used as a case study for the investigation into the optimization of the dry batch plant. Lean Manufacturing and TOC are optimization methodologies that could be employed to optimize the dry batch plant. Tools from these methodologies were used to investigate problems identified within the production process that were causing the batching plant to perform non-optimally. A time and motion study was conducted and a process flow chart was created to understand the production process. Wasteful activities were identified using a value stream map and a flow process chart was used to visualise the movement within the production process. A 5-Why analysis was conducted to determine the root causes. An optimization plan was created to eliminate the wasteful activities and the operational measures, that is throughput, inventory and operating expense, were used as to determine what the effect the optimization plan would have on the wasteful activities (Lean Manufacturing) found within the batching plant and the organisation. The results of the combined effect of the optimization plan are discussed focusing on the improvements in the operational measures and the increase in profit from sales. Future research is suggested to improve the benchmarking of the optimization plan and any future improvements that the organisation might implement. / MSc (Development and Management Engineering), North-West University, Potchefstroom Campus, 2015

This dissertation reports the investigation and combination of optimization methodologies and the result of implementing them within a production environment. A literature survey was conducted on the optimization methodologies Lean Manufacturing and theory of constraints (TOC). A number of production optimization methodologies were studied and considered for application to the case study organisation. Due to the small size and relative simplicity of the operation, these methodologies had to be simplified and combined into a more relevant form. A refractory manufacturer was used as a case study for the investigation into the optimization of the dry batch plant. Lean Manufacturing and TOC are optimization methodologies that could be employed to optimize the dry batch plant. Tools from these methodologies were used to investigate problems identified within the production process that were causing the batching plant to perform non-optimally. A time and motion study was conducted and a process flow chart was created to understand the production process. Wasteful activities were identified using a value stream map and a flow process chart was used to visualise the movement within the production process. A 5-Why analysis was conducted to determine the root causes. An optimization plan was created to eliminate the wasteful activities and the operational measures, that is throughput, inventory and operating expense, were used as to determine what the effect the optimization plan would have on the wasteful activities (Lean Manufacturing) found within the batching plant and the organisation. The results of the combined effect of the optimization plan are discussed focusing on the improvements in the operational measures and the increase in profit from sales. Future research is suggested to improve the benchmarking of the optimization plan and any future improvements that the organisation might implement. / MSc (Development and Management Engineering), North-West University, Potchefstroom Campus, 2015

Syfte – Studiens syfte var att utveckla KDI-metoden till att även inkludera egentillverkade artiklar. För att kunna uppfylla syftet har det brutits ned i tre frågeställningar: Vilka data och analysverktyg i KDI-metoden berör egentillverkade artiklar? Vilka verktyg bör tillkomma i fas två för att kunna analysera egentillverkade artiklar? Vilken ytterligare data bör tillkomma i fas ett för att kunna inkludera egentillverkade artiklar? Metod – Tillvägagångssättet för studien innefattade en litteraturstudie, en fallstudie samt en analytisk konceptuell ansats. För att besvara den första frågeställningen genomfördes fallstudien innehållande intervjuer, observationer samt dokumentstudier på fallföretaget Kinnarps, Skillingaryd. Insamlad data tolkades och analyserades i förhållande till ett teoretiskt ramverk som genererade ett resultat. För att besvara den andra och tredje frågeställningen genomfördes en analytisk konceptuell ansats utifrån tidigare framtagna teorier som senare sammanställdes i en modell. Resultat – Steg ett till fyra i fas ett samt steg sju och åtta i fas två i KDI-metoden berör egentillverkade artiklar. En modell för inkludering av egentillverkade artiklar skapades där det framgår vilka analysverktyg samt data som bör undersökas. De verktyg som tagits fram baseras på teorier kring bland annat värdeflödeskartläggning, materialhantering och modell för make-or-buy beslut. Utifrån dessa verktyg kunde det tolkas vilka data som bör tillkomma för egentillverkade artiklar. Implikationer – I denna studie framgår det att ingen ny litteratur har upprättats utan kombinationer av redan existerande teorier presenteras. Teorin kring KDI-metoden skulle kunna förändras utifrån det sidoresultat som presenteras i examensarbetets sjunde kapitel. Verksamheter som applicerar KDT-metoden skulle kunna öka kunskapen för KDT och därmed förbättra verksamheten internt. Metoden hjälper även till vid analys för både externa och interna flöden. Begränsningar – KDI-metoden är i nuläget relativt ny och ej testad utanför det kontext som den är utformad för. Detta har resulterat i att författarna ej har kunnat styrka denna litteratur utifrån andra forskare. Fokus har legat på att finna teorier till kunddriven tillverkning kring värdeflödeskartläggning, materialhantering med mera. Önskvärt hade varit att genomföra ytterligare litteraturstudier för att finna lämpliga utvecklingsområden. Nyckelord – KDI-metoden, materialhantering, SWOT-analys, försörjningskedja, värdeflödeskartläggning, produktionslayout. / Purpose – The purpose of the study was to develop the CDP-method to include also manufacturing items. In order to help answering the purpose, three questions have been defined: Which data and analytical tools in the CDP-method affect manufactured items? Which tools should be added in the second phase in order to analyse manufactured items? Which additional data should be included in the first phase in order to include manufactured items? Method – The procedure for the study contain a literature study, case study and an analytical conceptual approach. In order to answer the first question, a case study was performed with interviews, observations and document studies at Kinnarps, Skillingaryd. The received data were interpret and analysed in relation to the theoretical framework that generated a result. In order to answer the second and third question, an analytical conceptual approach were conducted from previous theories that later was compiled in a model. Findings – Step one to four in the first phase and step seven and eight in the second phase of the CDP-method affect manufactured items. A model for included manufactured items has been created where analytical tools and data are presented that should be investigated. The tools that are introduced are based on theories within value stream mapping, material handling and a model for make-or-buy-decision. Based on these tools, it could be interpreted which data that should be created for manufactured items. Implications – It appears in this study that no new literature has been created but combinations of already existed theories are presented. The theory within the CDP- method could be changed from results that were founded when the CDP-method was applied at the case company. This is presented in the bachelor thesis seventh chapter. Companies that apply the CDM-method could increase the knowledge for customer driven manufacturing and improve the company internally. The method also assists when analysing both external and internal flows. Limitations – Today the CDP-method is relative new and not applied outside the context that it is designed for. One result of this is that the authors have not confirmed these literatures by other researcher. The focus has been to find theories to customer driven manufacturing within value stream mapping material handling and so on. It would have been desirable if additional literature studies could be performed in order to find appropriate development areas. Keywords – CDP-method, material handling, SWOT-analysis, supply chain, make- or-buy analysis, value stream mapping, production layout, total cost of ownership.

An initial review of literature concerned with commercial and industrial office design indicated the need to research and develop a method for the design of the management systems of offices with the purpose of improving the operational effectiveness and alignment to strategy. In particular the literature review indicated that the application of lean methods, in non-manufacturing areas is comparatively rare. A critical review of the literature identified that Value Stream Mapping has been used to map mechanistic task activities, however, a need was identified for a new generation of Value Stream Mapping to map mixed mechanistic and organic task activities. To complement the literature survey and discover if there were significant variables (e.g. task uncertainty, interdependence, task complexity, mechanistic / organic structures, risk, task analysability etc) influencing office design, pilot studies were carried out in a mechanistic and organic office. Several additional variables were identified. From the pilot studies combined with the literature review a conceptual model was formulated which provides guidelines for managers enabling them to design the management systems fully taking all the variables into account. The conceptual model was then tested using a multiple case study design of two small consulting type offices that exhibited mixed mechanistic and organic characteristics. This resulted in an improved version of the model which was then further validated. This validation based upon the opinions of office managers focused mainly on identifying the practical usefulness of the model from an industrial perspective. Following the validation a final form of the model has been proposed in this research. It remains for future researchers to fully test the model by applying it in a wider range of offices. This study makes an explicit contribution to the redesign of offices as well as the utilisation of Value Stream Mapping to the mechanistic and the organic task activities within commercial and industrial offices.

In today’s society, businesses and organizations are facing increasing challenges to change and adapt to a digitizing world. In order to stay relevant in the market, businesses need to work constantly on developing and improving the efficiency of its various processes. This study is designed as a case study at MittSverige Vatten & Avfall which is a municipal corporation in Sundsvall municipality. Its goal is to be a leader in its sector by the year 2021. The study’s objective was to investigate if the digitization of information gathering could bring benefit to a company and its customers. The investigation has focused on the digitization of information gathering from the customer's water meter. The study's objective has been to identify and analyze how digitization impacts business processes and its financial condition with help from value stream mapping and a customer survey. The study was conducted with the support of written and web based literary sources. A survey as well as interviews was conducted. An investment analysis has been conducted to study and evaluate the benefits that the investment brings the customer and MittSverige Vatten & Avfall regarding cost. The study proved that the digitization of water meters would mean an improvement for both MittSverige Vatten & Avfall and its customers. / Verksamheter och organisationer står i dagens samhälle framför ökande utmaningar till förändringar och anpassning till en digitaliserande värld. För att kunna fortsätta vara relevant på marknaden så behöver verksamheter arbeta ständigt med utveckling och effektivisering av dess olika processer. Denna studie är utförd som en fallstudie hos MittSverige Vatten & Avfall som är ett kommunalt bolag i Sundsvall kommun. Studien hade som syfte att undersöka vad digitalisering av informationsinhämtning kunde tillföra för nytta för ett företag och dess kunder. Undersökningen har fokuserat på digitalisering av informationsinhämtning från kundens vattenmätare. Studien har haft som mål att kartlägga och analysera digitaliseringens effekt på verksamhetens processer och ekonomiskt tillstånd med hjälp av värdeflödesanalys och kundundersökning. En enkät och intervjuer har utförts. En investeringsanalys har utförts för att studera och värdera nyttan som investeringen tillför kunden och MittSverige Vatten & Avfall med hänsyn till kostnaden. Studien bevisade att en digitalisering av vattenmätare skulle innebära en förbättring för både MittSverige Vatten & Avfall och dess kunder.

Este trabalho apresenta conceitos relacionados ao pensamento enxuto, e mais especificamente, ao mapeamento de fluxo de valor (MFV), inseridos no contexto hospitalar, destacando exemplos encontrados na literatura e a análise de um caso prático conduzido pelo autor. Com a elaboração do trabalho, foi possível concluir que não existe um modelo de mapeamento de fluxo de valor padronizado para aplicações de lean em ambientes hospitalares. De maneira geral, a utilização do MFV em hospitais se dá através de adaptações da manufatura que não levam em conta todas as atividades que interferem no fluxo dos pacientes, como o fluxo de informações e de materiais. Para contornar esse problema, esta dissertação visa propor um novo modelo de MFV, voltado para ambientes hospitalares, que consiga contemplar em um único mapa todos os fluxos que interferem diretamente na duração do tratamento do paciente e sirva como modelo padrão para aplicações de lean em hospitais. Para isso, foi realizado um levantamento bibliográfico, que buscou identificar, no período de 2000 a 2013, os principais modelos de MFV atualmente empregados em implantações de lean healthcare e identificar as principais características e pontos positivos de cada um. Estes pontos positivos serviram como requisitos para a elaboração do novo modelo, passando a integrar um único mapa. Com a aplicação prática desse novo MFV, foi possível identificar os gargalos operacionais e inúmeros desperdícios que interferem no tratamento do paciente e que não poderiam ser identificados pelos outros modelos de mapeamento estudados. É possível concluir, com os resultados alcançados, que o modelo proposto atendeu aos objetivos definidos e demonstrou ser uma ferramenta valiosa para identificação de desperdícios em ambientes hospitalares. / This thesis presents lean thinking concepts focused on healthcare environments and more specifically on the value stream mapping (VSM). The research could concluded that there is no value stream map standardized for lean healthcare applications. In general, the use of VSM in hospitals are made by manufacturing adaptations that do not take into account all activities that interfere in the patient flow, such as information and material flow. To solve this problem, this research aims to propose a new VSM model for healthcare, which could contemplate all activities that directly affects the treatment time and also be a template for lean healthcare applications. Therefore, the focus in the literature review was to identify the main healthcare VSM models published between 2000 and 2013 and the key characteristics and strengths of each. These strengths were used as requirements for the new mapping model elaboration and were integrated in a single map. The practical application, conducted by the author, identified operational bottlenecks and numerous wastes that interfere in the patient\'s treatment that could not be identified by the other mapping models studied. In conclusion, the new VSM model proposed has achieve the defined goals and proved to be a valuable tool for identifying waste in hospital environments.

The rapid rise in global population and market demands have mandated industries to introduce better and quality products to meet up their rushing needs. However, achiev-ing such goals need optimal production system and robust strategies. Exploring in depth it can be visualized that most of the manufacturing set ups suffers losses or relatively lower benefits due to improper and high wastages. Hence it is very important for man-ufacturing industries to explore the techniques which help them to improve their pro-duction system. The key techniques from Lean Manufacturing (LM) such as Value Stream Mapping (VSM) and Ishikawa diagram were explored in this work for enhanc-ing production capacity, reducing rework, reducing wastages and arriving to a well-defined optimal process flow which in turn help in achieving higher productivity. How-ever, the implementation of Lean and Value stream mapping depends on the production scale and has its own significance to different manufacturing setup. With that motive, in this thesis work the emphasis was made on exploring VSM technique for better pro-duction optimization in manufacturing sector.

Este trabalho apresenta conceitos relacionados ao pensamento enxuto, e mais especificamente, ao mapeamento de fluxo de valor (MFV), inseridos no contexto hospitalar, destacando exemplos encontrados na literatura e a análise de um caso prático conduzido pelo autor. Com a elaboração do trabalho, foi possível concluir que não existe um modelo de mapeamento de fluxo de valor padronizado para aplicações de lean em ambientes hospitalares. De maneira geral, a utilização do MFV em hospitais se dá através de adaptações da manufatura que não levam em conta todas as atividades que interferem no fluxo dos pacientes, como o fluxo de informações e de materiais. Para contornar esse problema, esta dissertação visa propor um novo modelo de MFV, voltado para ambientes hospitalares, que consiga contemplar em um único mapa todos os fluxos que interferem diretamente na duração do tratamento do paciente e sirva como modelo padrão para aplicações de lean em hospitais. Para isso, foi realizado um levantamento bibliográfico, que buscou identificar, no período de 2000 a 2013, os principais modelos de MFV atualmente empregados em implantações de lean healthcare e identificar as principais características e pontos positivos de cada um. Estes pontos positivos serviram como requisitos para a elaboração do novo modelo, passando a integrar um único mapa. Com a aplicação prática desse novo MFV, foi possível identificar os gargalos operacionais e inúmeros desperdícios que interferem no tratamento do paciente e que não poderiam ser identificados pelos outros modelos de mapeamento estudados. É possível concluir, com os resultados alcançados, que o modelo proposto atendeu aos objetivos definidos e demonstrou ser uma ferramenta valiosa para identificação de desperdícios em ambientes hospitalares. / This thesis presents lean thinking concepts focused on healthcare environments and more specifically on the value stream mapping (VSM). The research could concluded that there is no value stream map standardized for lean healthcare applications. In general, the use of VSM in hospitals are made by manufacturing adaptations that do not take into account all activities that interfere in the patient flow, such as information and material flow. To solve this problem, this research aims to propose a new VSM model for healthcare, which could contemplate all activities that directly affects the treatment time and also be a template for lean healthcare applications. Therefore, the focus in the literature review was to identify the main healthcare VSM models published between 2000 and 2013 and the key characteristics and strengths of each. These strengths were used as requirements for the new mapping model elaboration and were integrated in a single map. The practical application, conducted by the author, identified operational bottlenecks and numerous wastes that interfere in the patient\'s treatment that could not be identified by the other mapping models studied. In conclusion, the new VSM model proposed has achieve the defined goals and proved to be a valuable tool for identifying waste in hospital environments.

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>