Este trabalho apresenta um método que visa auxiliar os agentes de mudança na condução de processos de implementação de sistemas de produção enxuta, cujo conceito tem sido largamente aplicado em diversas indústrias no Brasil, tais como a Ford, a GM, a Visteon, a Eaton, a Delphi, a Meritor, para citar apenas algumas. Entretanto, principalmente nas empresas que possuem produtos com grande variedade de peças e componentes, e com características distintas de demanda, muitos gerentes têm encontrado dificuldades ao tentar implementar um sistema de produção enxuta. O método é desenvolvido a partir de uma ampla revisão bibliográfica em torno do conceito de gerenciamento da mudança e melhoria organizacional, bem como dos princípios e das principais práticas e ferramentas enxutas. Com isso, são estudados com mais profundidade o mapeamento do fluxo de valor, a produção puxada, o sistema de controle Kanban e o layout celular. Em seguida, o método é validado empiricamente por meio de duas aplicações, a primeira numa empresa produtora de bebedouros e a segunda numa empresa produtora de tanques para armazenagem e resfriamento de leite. / This work presents a method that aims to help the change agents in the Lean Production Systems implantation, whose concept has been applied in several industries in Brazil, such as Ford, GM, Visteon, Eaton, Delphi, Meritor, etc. However, mainly in the companies with great variety of goods and components, many managers have been difficulties to implement a lean production system. The method is developed from a wide bibliographical revision around change and improvement management concept, as well as lean production tools and techniques. It is studied value stream mapping, pull production, Kanban control system and cellular layout. The method is empirically validated in two applications, the first application is in a drinking fountain company, and the second one is in a tank of milk storage company.

Este trabalho propõe um método de representação e análise de cadeias de suprimentos que visa permitir a identificação e conseqüente eliminação dos desperdícios que ocorrem ao longo de uma cadeia produtiva. Fundamentado nos conceitos de gestão da cadeia de suprimentos, produção enxuta e modelagem de empresas, este trabalho tem como principal justificativa a necessidade de se desenvolver mecanismos que possibilitem a integração entre empresas, melhorando os níveis de coordenação e sincronização dos fluxos de materiais e informações. O mapeamento do fluxo de valor, técnica de modelagem desenvolvida por ROTHERS & SHOOK (1998), visa auxiliar a obtenção de sistemas produtivos enxutos e foi utilizada como base para o desenvolvimento do método. Dois aspectos são levados em conta para a proposição do método: o primeiro diz respeito ao conteúdo de informações dos modelos e o segundo ao procedimento de aplicação. A principal característica do método é a decomposição em três níveis de mapeamento, indo de um nível mais genérico para um nível de maiores detalhes. Uma ilustração de um caso hipotético de aplicação é fornecida como exemplo. Como conclusões são expostas as vantagens e limitações percebidas no método. Os trabalhos futuros sugeridos se referem à avaliação, aplicação e complementação do método. / This work proposes a method for supply chain representation and analysis to allow the identiJication and consequent elimination of the waste in the production chains. The fundamental concepts this work is based on are: supply chain management, lean production and enterprise modeling. The main reason for the development of this research is the need of developing tools and mechanisms to help the integration between enterprises, improving the coordination and synchronization of the material and information flows. The Value Stream Mapping technique, developed by ROTHERS & SHOOK (1998), which helps the design of lean production systems, is used as a basis for the development of the method. Two aspects were observed during the development of the method: the first one deals with the information content of the models and the second one with the application procedure of the method. The main characteristic of the method is the decomposition in three levels of mapping, from a generic level to a more detailed one. An illustration based on a hypothetic case is given as an example. At the conclusion of this work the advantages and limitations of the method are discussed. Some future researches are suggested based on the evaluation, application and complementation of the method.

Orientador: Paulo Correa Lima / Dissertação (mestrado profissional) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-10T02:07:53Z (GMT). No. of bitstreams: 1 SantosNeto_FaustoFerreirados_M.pdf: 2574451 bytes, checksum: e24cbfc7b809b1748a11da92aa5cca33 (MD5) Previous issue date: 2006 / Resumo: Atualmente, numa economia globalizada, a sobrevivência das Empresas depende de suas habilidades e flexibilidades de inovar e efetuar melhorias continuas. Como resultado, as Empresas vem buscando incessantemente novas ferramentas de gerenciamento, que as direcionem para uma maior competitividade através da qualidade e produtividade. Este trabalho sugere um método para implementação de um Sistema de Manufatura Enxuta, numa empresa automobilística instalada no Brasil, que permita níveis mundiais de performance. Neste trabalho é feita uma revisão bibliográfica que engloba uma abordagem histórica do assunto e uma apresentação dos conceitos nos quais a Manufatura Enxuta está estruturado, além de ser apresentado um caso prático de implementação e abordagem gerencial, relatando seus estágios e os resultados obtidos. O que foi extremamente relevante é que esta implementação alcançou excelentes resultados, que foram obtidos sem investimentos em pessoal ou maquinários, mas apenas na no estudo e na implementação das ferramentas de manufatura enxuta Por fim, é feita uma análise relacionada a essa abordagem / Abstract: Nowadays, in the global economy, organizations survival depends on their capacity and flexibility to do continuous improvements, which take them to harder competitively through quality and productivity This work suggest a method for implementation, a Lean Manufacturing System, in an automobilist company installed in Brazil, that allow the company to reach a best industrial performance. This job is a bibliographic revision that inc1udes historic assumptions and presentation of concepts regarding lean manufacturing structure besides practice presentation and manager approach relating phases and results achieved. What was extremely relevant is that this implementation reached excellent results, which were obtained without investments in personal or machine, but only in the study or relocation of lay out and implementation of lean manufacturing tools. And the end it' s done related analyses of total approach / Mestrado / Planejamento e Gestão Estrategica da Manufatura / Mestre em Engenharia Mecânica

Esta dissertação tem como foco a aplicação da metodologia enxuta, em um ambiente de trabalho público-administrativo, usando as técnicas do sistema de gerenciamento Lean Office. O objetivo da pesquisa foi identificar e combater os desperdícios encontrados no processo de atendimento a clientes externos para diminuir o tempo de processamento dos pedidos de prestação de serviços recebidos pelo Laboratório de Integração e Testes (LIT), do Instituto Nacional de Pesquisas Espaciais (INPE), em São José dos Campos SP. O trabalho foi realizado em três etapas, sendo iniciado com a metodologia do Mapeamento do Fluxo de Valor (MFV), usada para descrever os estágios do processo em estudo e identificar oportunidades potenciais de melhoria. A seguir, utilizando-se os fundamentos da metodologia kaizen, foi desenvolvido um plano de ação que norteou a implantação de novas rotinas operacionais. Na terceira etapa, finalmente, o MFV foi revisado para refletir as melhorias consideradas e delinear o estado futuro do processo. Usadas de maneira integrada, estas metodologias orientaram o desenvolvimento de novos procedimentos operacionais, que possibilitaram reduzir em 22% (equivalente a aproximadamente três dias de trabalho) o tempo de processamento dos pedidos. / This dissertation focuses on the application of lean methodology in a public administration work environment, using the techniques of Lean Office management system. The objective of this research was to identify and combat the waste found in the attendance of the customers of the Integration and Test Laboratory (LIT), the National Institute for Space Research (INPE) in Sao Jose dos Campos - SP by reducing the orders processing time. The work was conducted in three stages, starting with the methodology of Value Stream Mapping (VSM), used to describe the stages of the process under study and identify potential opportunities for improvement. Then, using the kaizen methodological basis, an action plan was developed to drive the implementation of new operational routines. In the third stage, finally, the VSM was revised to reflect the improvements considered and outline the future state of the process. Used in an integrated manner, these methodologies guided the development of new operational procedures, that enabled 22% reduction (equivalent to three working days approximately) in the orders processing time.

Context: Software testing is a crucial area in software development. It has been found that there is little evidence on how testing is performed in software automotive domain. Challenges in this domain have not yet been fully evaluated. Furthermore, interactions between test procedures, and other activities of software development are left unexposed. Assessment of test process is an important part of improvement initiatives. Objectives: In this study we perform an in-depth investigation to identify challenges which lead to wastes in test process in the context of automotive software domain. To this end, we also identified strengths that add value in test process. Methods: We performed a Case study at a Sweden based large automotive organization. To this end, we conducted semi-structured interviews and used Grounded Theory method for interview data analysis. We used Value Stream Mapping (VSM), a Lean methodology tool for test process assessment. Furthermore, we conducted Systematic Literature Reviews to look for evidence of similar problems and solutions offered in peer-reviewed literature. Results: We grouped the identified challenges and strengths into 10 and 4 categories respectively. We also identified 7 kinds of waste and 4 kinds of values based using VSM. Based on systematic literature reviews, we proposed 7 solution proposals, an agile process model with practices. Conclusions: We conclude that VSM is an efficient tool in eliciting improvement potentials in software testing context using qualitative data. In regard to solution proposals, we propose further empirical work to evaluate the solution proposals themselves and tailor to company needs. However, the results obtained through this study can be compared to test processes at other companies in automotive domain. / kasoju.abhinaya@gmail.com

In a theoretical part of this work there is introduced a general view on logistics and its development, than a view on creating value for customer, basics of lean production, lean thinking and following methods as Six Sigma and Value Stream Mapping. At the end of the theoretical part there is mentioned outsourcing of logistics services and view on relationship between logistics provider and a client. In a practical part there is introduced a project of in-plant logistics optimalization in a factory producing steel pannels for MINI Cooper production. At the beginning there is introduced the factory itself, logistics services provider and a background of the project birth. Than there is a step by step description of a work on the project respecting a DMAIC methodology, it means that it's a classical example of a Six Sigma project using a Value stream mapping tool.

Transporter har blivit allt viktigare i vårt samhälle och beräknas fortsätta bli ännu viktigare de kommande åren. En stor utmaning för transportleverantörer är att bevara en hög kvalitetsnivå och samtidig hålla nere miljöpåverkan vilket sätter hög press på effektivisering av processerna. I dagsläget finns det få studier som undersökt möjligheten att effektivisera den faktiska transportprocessen genom styrningsmodeller som exempelvis lean. Därav syftar studien till att undersöka hur transportprocesser kan effektiviseras med hjälp av lean. Studiens teoretiska referensram består främst av Seven Waste Framework och Value Stream Mapping. Ett kvalitativt angreppssätt har använts och insamling av data har skett genom observationer kombinerat med intervjuer för att få god förståelse för processen. En anpassad metod har använts för att lättare kunna dokumentera och visualisera flödet för att få god förståelse för processen. Den anpassade metoden innebär att först utforma en VSM över processen, sedan att identifiera slöserier i processen för att till sist definiera en strategi för att effektivisera eller helst eliminera slöserierna. Resultatet av studien är att lean är ett resultatrikt verktyg för att effektivisera transportprocesser samt att VSM skapar god förståelse av processen vilket gör att lean och VSM är en framgångsrik kombination. / Transportation has increasingly become important in today’s society and is expected to continue to grow rapidly in the following years. A major challenge for transport providers is to maintain a high quality level and at the same time minimize the environmental impact, which puts pressure on the efficiency of the processes. At present, only a few studies which review the possibility to rationalize the actual transportation process through different accurate models such as lean. Therefore the study aims to review how transport processes can be streamlined using lean. The theoretical reference framework of the study consists mainly of Seven Waste Framework and Value Stream Mapping. A qualitative approach has been used and in order to give an overall understanding for the process, the data collection was made both through observations as well as by interviews. A customized method has been used to simplify the documentation and visualizing the process flow, and hence create a better understanding of the process. The steps to the customized method firstly designs a VSM of the process, then identifies waste in the process to finally define a strategy to minimize, or preferably eliminate, the waste. The study shows that lean is an effective tool for optimization of transport processes as well as VSM creates a good insight of the process, which makes lean and VSM a powerful combination.

En säsongsbaserad tillverkning kan innebära svårigheter för företag att möta kundefterfrågan och hålla lagernivåerna nere. En strategi för att möta en varierande efterfrågan är automatisering, vilket kan leda till en högre produktivitet och kapacitet, samtidigt som det kan begränsa flexibiliteten. För ökad flexibilitet kan gradvis automatisering av en anläggning göra det möjligt att integrera processer och få en stabil tillverkning. Arbetets syfte är att skapa förståelse för hur en förändring av en del av en produktionslina påverkar flödet i produktionen, med hänsyn till förändrad maskinutrustning och kapacitet. Målet med arbetet är att skapa en modell som möjliggör produktionsplanering i ett flöde där empirisk data inte är tillgänglig. För att svara på syftet skapades frågeställningar för att behandla hur en produktionsplanering kan göras som är baserad på empirisk teoretisk data, hur flöden bör kombineras samt hur olika faktorer påverkar buffertar och ledtider i en produktion. Genom att använda teorier om lean production och lager kunde en matematisk modell skapas. Resultatet blev en modell som med hjälp av kända variabler kunde beräkna okända samt skapa en matematisk produktionsplanering. Slutsatsen visar på att det är möjligt att skapa en produktionsplanering baserat på empirisk teoretisk data, och att modellen är tillämpningsbar även på andra industrier eftersom den är anpassningsbar. / A season based production may lead to difficulties for companies to fulfill customer demand and to keep stocks to a minimum. Changing the production can lead to a higher productivity and capacity, meanwhile it may limit flexibility. A gradual automation makes it possible to interact different processes and to make a stable production. The purpose of this project is to gain an understanding of how a changed part of a production line affects the production flow, with changed capacity and machine equipment taken into account. The goal is to create a model that enables production planning in a flow where empirical data is not available. To answer the purpose, questions of the issue were created with a focus on how a production plan can be done with only empirical theoretical data, how flows can be combined and finally how factors affect the buffers and lead time. By combining theories of lean production and inventory, a mathematical model could be created. The result was a model that with the help of known variables could figure out unknown and thereby create a mathematical production plan. The conclusion shows that it is possible to create a production plan based on empirical theoretical data, and that the model can be applied to other industries as well because of its customizability.

A few years back, almost every garment manufacturer industry started implementing “lean Manufacturing.” Garments manufacturing is one of the oldest manufacturing systems, compromising a higher number of critical operations. The main performance indicators in the garment industry are the lead time, production rate, more wastage, and labor intensity. To remain competitive in the global market, the most important task for garments manufacturers is to reduce lead time and waste, which is also essential for productivity and long-term stable development. A headlong rush to reduce lead time and waste by turning into lean and responsive manufacturing has created an urgency for researchers and practitioners to apply new tools and techniques for discovering wastages. This thesis focuses on the application of value stream mapping in the garments industry to implement lean manufacturing system. Value stream mapping (VSM) helps visualize Material Flow and Information Flows of all components, cycle times, and utilization of resources. VSM is a proven lean technique in identifying and eliminating wastes in accommodation with similar or identical product routings. The research approach adopted in this thesis is abductive. Qualitative has been collected by the structured and semi-structured interviews. A single case observation has been made to use VSM as a lean tool to achieve productivity improvement at a selected garment company. Both current and future state mapping of cutting section and sewing line scenarios are discussed using value stream concepts. This was analyzed along with the process lead time as standard minute value (SMV) calculation and two gaps as productive time and non-productive.  Finally, gain in productivity (increase output pcs, less worker, less working hours), increased productive time, and reduce non-productive time was calculated.

The intent of this thesis is to design a lean production process for a manufacturing plant owned by TOS KUŘIM - OS. a.s. The manufacturing process is analyzed using the value stream mapping method. The method is used to identify inefficient steps in the production process. Furthermore, the thesis offers solutions to the recognized problems, aiming to increase added value and minimize waste.