Master of Agribusiness / Department of Agricultural Economics / Vincent R. Amanor-Boadu / It is estimated that the animal health biologics sector will increase by over 27% between 2015 and 2020. This projection and the increasing competition among the sector’s players suggests need to find ways to enhance their efficiencies in manufacturing to sustain their relative competitiveness. One approach to enhancing efficiencies is to ensure that all work is done once, i.e., everything is done right the first time. This research focused on human error as a major source of inefficiency in manufacturing and hypothesized that addressing issues that reduce human error would contribute to reducing inefficiencies. The research used the Kaizen process to assess the before and after counts of human error in a biologics manufacturing unit of Z Animal Health Company (ZAHC). The study found that human error accounted for about 51% of all sources of error in the pre-Kaizen period and only about 34% of all errors in the post-Kaizen period, a reduction in excess of 33.3%. Given that humans are directly or indirectly responsible for all activities in the manufacturing process, the Kaizen process also contributed to a reduction in most other error sources. For example, errors in raw materials and components went reduced by about 50%. We tested the hypothesis that undertaking the Kaizen was statistically effective in reducing human error compared to all other errors using a logit model. Our results confirmed this hypothesis, showing that the odds ratio of human error in the post-Kaizen period was about 50% of the odds of non-human error. The research suggests that in a highly technical manufacturing environment, such as in animal health biologics, human errors can be a major problem that can erode competitiveness quickly. Focusing employees’ on root causes of errors and helping them address these through structured quality-enhancing initiatives such as Kaizen produce superior results. It is, therefore, suggested that when organizations discover human error as a major source of inefficiency, it is prudent to help employees understand what they do and how what they do contributes to the overall performance of the organization. This appreciation of how their actions fit into the big picture could provide a foundation upon which significant improvements can be achieved.

Firstly, the word KAIZEN is analysed in a theoretical part of this Master Thesis and the individual structures in organizations are described in next chapter. The requirements of relevant standards (ISO 9001, ISO 14001, ISO 27001, OHSAS 18001) are introduces, too. An audit, its types, sorts and processes of it are explained at the end of the theoretical part. A practical part contains “A project university - certifying authority – organisation”. The project deals with student´s involvement into the internal audits of selected organizations and gaining knowledge of audit processes. The project deals with competence evaluation of the internal audits´ implementation, too.

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / The textile sector presents a general problem, due to the increasing introduction of international products (Chinese, Hindu, etc.) due to the low cost of labor and the use of high-tech equipment, this forces companies in the field to improve their productive processes, produce more with less, and reduce costs from the most basic jobs. Therefore, it is proposed to implement the Lean methodology, focusing directly on the optimization of production processes using its various tools and a selection of indicators for monitoring the results. To validate, a case study was carried out in a real company that implemented the different Lean tools and the Kaizen matrix in the dyeing and finishing process, a process that presents a high percentage of defects. This allowed us to effectively reduce the number of reprocesses by a significant 8.14%, which allowed the company to save $ 184,320.42.

Kaizen implementation and other continuous improvement practices can be used by companies to lower manufacturing costs and increase product value. Kaizen activities are one way that wood products companies can increase their competitiveness. Being able to measure the effectiveness of Kaizen events is important to factors that contribute to Kaizen effectiveness as well as identifying the success of Kaizen implementation. However, little research has focused on the implementation of Kaizen and other continuous improvement methods within the wood products industry or on the perceptions of employees within this industry regarding either the motivators for, barriers to, and effectiveness of perceptions of Kaizen, or the drivers affecting Kaizen implementation. The goal of this research is to develop a tool to measure the effectiveness of Kaizen and to apply this tool to companies within the wood products industry. To accomplish this research goal, a case study approach was used in examining how two U.S. wood products companies implemented Kaizen and other continuous improvement initiatives and how employees at these companies viewed such implementation. As part of this case study, interviews were conducted with staff in each company and surveys were administered to production and non-production employees at each company. A tool was developed to measure the perceived effectiveness of Kaizen events, and this tool was tested using the survey data were collected from each company. The results from these analyses show statistically significant differences in how production employees across companies viewed the following: motivators related to cost and quality outcomes, as well as the success of other companies, as motivators for Kaizen; and barriers related to middle management, time, money, technology, and poor past experiences. Poor past experience with Kaizen were also viewed significantly differently by production and non-production employees in one of the companies studied. The results also show that perceptions of productivity improvements were the most significant predictor of the perceived effectiveness of Kaizen implementation. These results and the development of a tool to measure Kaizen will help guide and improve future Kaizen and other continuous improvement efforts within the wood products industry and provide insights for future research. / Master of Science

No / Purpose. The purpose of this paper is to explore the results of implementing the Kaizen approach in a caravan repairing project near the Jordanian–Syrian border in the Zaatari camp. Design/methodology/approach. The study is based on the exploratory qualitative research approach. The data were collected through interviews and on-site observation with employees who were involved with the caravan maintenance project and have adequate knowledge and information about this project. In this process, a fishbone diagram, a quality control tool, is used to recognize and explain a causal-effect relationship under the selected Kaizen theme. Findings. The findings suggest that the Kaizen approach was economical in terms of both money and time. Also, waste elimination can be achieved through a variety of tools and easily combined with the Kaizen approach. Implementing the Kaizen approach is an effective and reliable system that allows for the tackling of all types of inefficiencies in the caravan repairing project. Research limitations/implications. The findings of this study will help policy makers and managers put together suitable and effective policies that will assist those firms in overcoming the demands of customers and competitors to deliver high quality, inexpensive products in less time through the application of the Kaizen approach. This, in turn, will lead to improved quality, efficiency and productivity in the most cost-effective way. However, these results should not be generalized since they are only confined to the context of caravan repairing project. Originality/value. Very little research has been done that takes into account the contexts of developing countries. Additionally, most literature presents the use of Kaizen applications only in the manufacturing or production sectors. This study is the first to implement Kaizen as a continuous improvement technique in a caravan repairing project – a job shop industry different from the repetitive batch work environment that is usually associated with implementation of Kaizen. The current research should be of great interest to researchers, managers and professionals who wish to apply Kaizen approach as it is sustainable over time in similar projects.

Dagens samhälle präglas av ständiga förändringar i omvärlden. Internationalisering, globalisering och teknikutveckling är faktorer som leder till en ökad global konkurrens för företagen, vilket gjort att företag måste förbättra sina processer för att vara fortsatt konkurrenskraftiga och lönsamma. Det ständigt förändrade samhället kräver en väl genomförd ekonomistyrning för att företag ska kunna följa med i utvecklingen. Tillverkande företag är en stor del av det svenska näringslivet och måste därmed anpassa sig i den takt som globaliseringen sker. Många forskare har identifierat en kunskapslucka mellan ekonomistyrning i teori och praktik, då mycket forskning och utveckling av metoder inom ekonomistyrningen äger rum utan att man ser till hur detta uppfattas i praktiken.   Syftet med denna studie är att se vilka orsaker som kan förklara varför eventuella kalkylavvikelser uppstår i ett tillverkande företag inom fordonsindustrin i Sverige, samt hur dessa avvikelser kan påverkas och reduceras genom aktiv påverkan i det dagliga arbetet. Med intern benchmarking och Kaizen som verktyg vill vi öka kunskapen om dessa avvikelser och hur de kan påverkas, för att sedan reduceras och ge en bättre precision i förkalkylerna. Studien har genomförts med intervjuer, möten och observationer på två fallavdelningar i ett större tillverkande företag, för att skapa en djupare förståelse. Vidare har studien genomförts med ett kvalitativt tillvägagångssätt.   Resultaten vi funnit genom studien visar att möjligheten till att påverka de kalkylavvikelser som uppstår är stor. Möjligheten till aktiv påverkan skiljer sig beroende på vilken position i företaget respondenterna har. Studien visar att de flesta respondenter anser att tidsbrist är den största anledningen till att de inte använder sig mer av verktyg för påverkan såsom Kaizen och intern benchmarking. Vidare har vi funnit att medarbetare motiveras av mer än enbart monetär ersättning, såsom att få gehör och muntlig uppmuntran. Av studien kan konstateras att olika verktyg för effektiviseringar i teorin ofta framställs som oproblematiska och enkla att implementera, men i verkligheten och praktiken är det mer komplicerat. / Today´s society is characterized by constant changes in the business environment. Internationalization, globalization and development in technology are factors that lead to increased global competition between companies, why companies must improve their processes to remain competitive and profitable. The constantly changing society requires a well-implemented management control to keep up with the development, Manufacturing companies represents a big part of the Swedish industry. The companies must therefore adapt to the pace of globalization. Researchers have identified a gap in knowledge between management control in theory and practice. Research and development of methods for management control take place without ensuring how it is perceived in practice.   The purpose of this study is to define the reasons that explain why calculated deviations occur in the automobile industry in Sweden and how these deviations can be affected and reduced by active impact in the daily work. Our hope is to increase the knowledge about the deviations; how they can be affected, reduced and give a better precision in the calculations, with internal benchmarking and Kaizen as tools. The study was accomplished by interviews, meetings and observations of two departments in a large manufacturing company in order to create a deeper understanding. The study carried out with a qualitative approach.   The results we have found show that there is a great ability to affect the deviations. The opportunity for active impact differs depending on the respondent´s position in the company. The study shows that most respondents consider the lack of time as the main reason why they don´t use instruments for active impact, such as Kaizen and internal benchmarking. Furthermore we have found that employees are motivated by more than just monetary compensations, such as verbal encouragement and being noticed. The study concludes that different instruments for increasing efficiency in theory often is presented as unproblematic and easy to implement, but in reality and practice it is more complicated.

The thesis deals with the application of the Lean manufacturing and Kaizen ma-nagement in processes of production and logistics management and selected tools and techniques of lean manufacturing and Kaizen management. The research of the imple-mentation of the Lean manufacturing was conducted at the production departments of the company. It is necessary to involve the processes principles.We can say, that the introduction of lean manufacturing principles and application of Kaizen management is a significant competitive advantage. The aim of tools supporting the implementation of the principles of the Lean manufacturing and Kaizen management is the elimination of wasting, improving response to customer´s demands. The keeping of the principles of company culture with the transition from the concept company to concept my (our) company. These principles are applicable to systems in the mass production and the small batch production. The some methods and tools are applicable in the area of services and public administration. We can say, that into each activity can be found reserves which are wasting about the Lean manufacturing. We are able to reduce or eli-minate them with use right tools. The subject of research are a never-ending changes the set up manufacturing processes during the implementation of Lean manufacturing and next application of Kaizen management. The changes which were done was not concern only for new set of material flow, workplace layout, leveling and optimization work, but also changes focused to thinking of people who are involved in these changes or the changes affecting them. To evaluace of the success and applicability of the newly introduced methods were set up measurable indicators and methodology of their eva-luation. The results which are presented are important for the company where the re-search was conducted. The outputs is important for other companies and recommen-dations of general application can help their further development and help to futher de-velop scientic knowledges.

Due to an extremely competitive market in recent years, the sector of aviation industry requires speed and agility to meet their external customers needs. To be competitive, it is necessary to produce parts that will make a quality product quickly in a way to reduce costs and increase agility in manufacturing. This dissertation presents a case study conducted in an industry of the aerospace segment with the purpose of finding alternatives for productivity gain, using lean thinking tools, specially the kaizen events (KE), in the development of machining programs for CNC machines, interconnected by CAD-CAM software. This method has been used with success in several industries leading to efficiency gains in solving problems of productivity, at low cost. During the implementation of KE, the work team implemented the value stream mapping (VSM), as an attempt to increase the value added in the preparation of the machining program and to meet the needs of the internal customer (production department). By using this methodology it was possible to reduce the average time of the development cycle of the NC programs in approximately 50% and the average number of hours spent to create the programs was also reduced in approximately 51%. Among several opportunities found during the preparation of current VSM, one of the major contributions to the productivity improvement resulted from the adoption of the continuous working flow practice. / Com o mercado extremamente competitivo nos últimos anos, o setor da indústria aeronáutica necessita de agilidade e rapidez para atender às necessidades dos clientes externos. Para ser competitivo torna-se necessário produzir peças que irão compor o produto rapidamente e com qualidade, de forma a reduzir os custos e aumentar a agilidade na fabricação. Esta dissertação apresenta um estudo de caso realizado numa indústria do segmento aeronáutico com o objetivo de encontrar alternativas para obter ganhos de produtividade no desenvolvimento de programas de usinagem para máquinas CNC, interligadas a softwares CAD-CAM, por meio da aplicação de ferramentas do pensamento enxuto, com ênfase em eventos Kaizen (EK). Este método esta sendo utilizado em várias indústrias com êxito e proporcionando ganhos de eficiência na solução de problemas de produtividade, com custo baixo. Durante a execução do EK, a equipe de trabalho implementou o mapeamento do fluxo de valor (MFV), buscando aumentar o valor agregado na elaboração do programa de usinagem, visando atender às necessidades do cliente interno (produção). A aplicação da metodologia tornou possível reduzir o tempo médio do ciclo de desenvolvimento da programação CN em aproximadamente 50% e o número médio de horas gastas para a criação dos programas em aproximadamente 51%. Dentre as diversas oportunidades encontradas durante a elaboração do MFV atual, destaca-se a criação dos programas de usinagem em fluxo contínuo para a obtenção destas melhorias.

The goal of thesis is to implement Kaizen method into manufacturing process and so mineralize the scrap of production and at the same time get an numerical overview of the guarantee for the quality of product. Implementation this method will lead to elimination of existing random check of the process. Place: ABB s.r.o. Brno (company is specialized to production switchgears)

The thesis analyses a problem of improving the work environment and all the sections of an organisation. In the first part, the genezis, methods, theory and practical examples of Kaizen philosophy and 5S method are presented. In the second part, there is an instruction to make a system of presenting proposals of employees and the possible forms of its realisation. I dealt with assessment and finacial valuation of the given proposals. Finally, I propose documents for keepimg standards and increasing efficiency of the 5S method in a certain workplace.