Productivity advances generated from ‘lean manufacturing’ are self–evident. Plants that adopt ‘lean’ are more capable of achieving shorter lead times, less waste in the system and higher quality levels. The goal of this study was to ascertain which ‘lean’ tools and techniques are available for use. A matrix was constructed with a summation of the authors who agree that specific ‘lean’ tools will reduce cycle time. It was found that reduced set–up time and waste elimination are most affected by the implementation of ‘lean’ tools and techniques. An empirical study was conducted to confirm the results of the literature study. The respondents’ knowledge on the ‘lean’ tools was also tested. It was found that respondents have a sound understanding of set–up time; they agree that it must be reduced in the plant. Pre–scientific evidence and the response from the empirical study confirm that there is a substantial amount of waste in the factory. A current state value–stream map was drawn from a single welded part Product X. The value–stream was analysed to reduce the cycle time in the process, with the focus on set–up time reduction and waste elimination. The future state value–stream map was drawn, displaying astonishing results. A continuous improvement (kaizen) programme will help reduce the cycle time even further by making use of the other ‘lean’ tools discussed in this study. This programme forms part of the procedure to optimise cycle time. / Thesis (M.B.A.)--North-West University, Potchefstroom Campus, 2012.

Most research studies in the batch process control problem are focused on optimizing system performance. The methods address the problem by minimizing single criterion such as cycle time and tardiness, or bi-criteria such as cycle time and tardiness, and earliness and tardiness. This research demonstrates the use of Stochastic Utility Evaluation (SUE) function approach to optimize system performance using multiple criteria. In long production cycles, the earliness and tardiness weight (utility) of products vary depending on the time. As the time approaches the due-date, it affects contractual penalties, loss of customer goodwill and the storage period for the completed products. It is necessary to reflect the weight of products for earliness and tardiness at decision epochs to decide on the optimal strategy. This research explores how stochastic utility function using stochastic information can be derived and used to strategically improve existing approaches for the batch process control problem. This research first explores how SUE function can be applied to existing model for bi-objective problem such as cycle time and tardiness. Benchmark strategies using SUE function (NACH-SUE, MBS-SUE, No idle and full batch) are compared to each other. The experimental results show that NACH-SUE effectively improves mean cycle time and tardiness performance respectively than other benchmark strategies. Next, SUE function for earliness and tardiness is used in an existing model to develop a tri-objective problem. Typically, this problem is very complex to solve due to its trade-off relationship. However SUE function makes it relatively easy to solve the tri-objective problem since SUE function can be incorporated in an existing model. It is observed that SUE function can be effectively used for solving a tri-objective problem. Performance improvement for averaged value of cycle time, earliness and tardiness is observed under a comprehensive set of experimental conditions.

The Health Care System has struggled with many problems such as medical errors, poorly designed processes, waste, and customer dissatisfaction. The Lean Six Sigma methodology has been shown to be efficient in solving problems in the manufacturing industry and in services, as well. In this study, a framework for applying Lean Six Sigma to the health care industry is presented. The framework depicts a systematic methodology to solve problems typically found in this industry. A case study is also presented on how to apply this framework. The DMAIC Model has been conducted in an Imaging Department to identify the root causes of problems and to define a future state of the process

Anhand eines Referenzmodells für ein automatisches Lager mit zwei Regalbediengeräten in einer Gasse wurde ein Algorithmus entwickelt, der für einen bekannten Auftragspool eine (Batch-) Optimierung und beim Einsatz von Mehrfachlastaufnahmemitteln zusätzlich eine Tourenoptimierung vornimmt. Die Spiele beider Geräte werden aufeinander abgestimmt, die Spielzeit wird minimiert. Es liegt ein Berechnungswerkzeug vor, mit dem die Spieldauer beim Einsatz von zwei Geräten und überlagerten Bedienbereichen ermittelt werden kann. Die Ergebnisse sind auf automatisierte Brückenkrane mit überlagerten Bedienbereichen übertragbar. Dazu wird ein Anwendungsbeispiel vorgestellt.

The aim of the diploma thesis “Value stream mapping” is to analyse the montage workplace of the company IFE-CR, a.s. with focus on the value stream and the methods of lean production. The thesis aims to identify priorities for applying lean production methods at the montage workplace and to propose concrete measures in order to reduce different types of wasting. The first part of the thesis is dealing with the theory, understanding the main principles and methods of lean production, as well as with the method of value stream mapping. The second part is dealing with value stream analysis of the montage workplace and proposes concrete measures to reduce wasting and to increase the production effectiveness, respectively to improve the material stream trough implementation of selected lean production methods in the montage workplace.

The aim of this master’s thesis is to propose the steps leading to the improvement of the financial situation of a mid-sized manufacturing company. In order to achieve this aim, the financial analysis is performed. It defines the company’s weaknesses and it serves as a background for a suggestion for corrective actions leading to the improvement. Based on the measurability of the corrective actions, the comparison of the current and predicted situation is made in the final conclusion. It is realized with the Index IN05 bankruptcy model. The corrective actions proposed aim in particular at the operational and production management. They focus mainly on the weaknesses defined by the financial analysis – reduction of inventories and increase of marginal profit in order to strengthen liquidity, reduce debt ratio and improve financial health score in general.

Anhand eines Referenzmodells für ein automatisches Lager mit zwei Regalbediengeräten in einer Gasse wurde ein Algorithmus entwickelt, der für einen bekannten Auftragspool eine (Batch-) Optimierung und beim Einsatz von Mehrfachlastaufnahmemitteln zusätzlich eine Tourenoptimierung vornimmt. Die Spiele beider Geräte werden aufeinander abgestimmt, die Spielzeit wird minimiert. Es liegt ein Berechnungswerkzeug vor, mit dem die Spieldauer beim Einsatz von zwei Geräten und überlagerten Bedienbereichen ermittelt werden kann. Die Ergebnisse sind auf automatisierte Brückenkrane mit überlagerten Bedienbereichen übertragbar. Dazu wird ein Anwendungsbeispiel vorgestellt.

Dagens industrier utvecklas snabbare och ständigt uppstår nya teknikutvecklingar som skapar nya krav och kräver förändringar inom tillverkningsindustrin. Eliminering av flaskhalsar är viktigt inom läkemedelsindustrin för att möta den ökade efterfrågan. Med tanke på att läkemedelsindustrin växer har polymerase chain reaction-tekniken (PCR) blivit en av de mest värdefulla teknikerna inom biovetenskap, diagnostik och rättsmedicin. Utvecklingen av PCR-teknik drivs av flera marknadsaktörer och skapar hård konkurrens. På grund av den höga konkurrensen är det avgörande att främja teknisk utveckling och skapa en optimal produktion inom läkemedelsindustrin för att möta marknadens efterfrågan. Det kan vara kostsamt att producera pålitlig utrustning inom läkemedelsindustrin. För att skapa affärsmål och analysera förbättringsmöjligheter inom produktionsprocessen kan optimeringssystem skapas med hjälp av simulering. Genom att skapa en virtuell modell kan data samlas för att identifiera problem inom tillverkningsindustrin. Genom flödessimulering kan en flaskhalsanalys skapas med fokus på väntetider, cykeltider och genomströmning. Denna studie svarar på forskningsfrågorna: (1) Vilka problem identifierar flödessimuleringar vid analys av prestanda och flaskhalsar för förpackningslinjer inom läkemedelsindustrin? (2) Vilka effekter får lösningsförslaget på prestandan för flaskhalsflödet i produktionsprocessen? Genom att simulera olika scenarier och identifiera problem relaterade till resursanvändning och prioriteringar vid sammanfogningspunkter kan lösningar på flaskhalsar identifieras. Genom att jämna ut prioriteringarna och använda buffertlager kan företag skapa ett jämnare flöde och förbättra motståndskraften i sina tillverkningssystem. Studien visar att design- och layoutval har en betydande effekt på den totala genomströmningen, vilket betonar vikten av noggrann layoutplanering och optimering inom läkemedelsindustrin. Genom att förbättra nyckeltal som medeltid mellan fel och medeltid mellan reparation kan företag öka genomströmning, produktivitet och effektivitet samtidigt som de uppnår ekonomisk, ekologisk och social hållbarhet. Rekommendationer för framtida studier inkluderar att undersöka operatörsplacering och maskinhastighetens inverkan på väntetiden. / Today's industries are developing at a faster pace and new technological developments are constantly being developed that create new demands and require changes within the manufacturing industry. Eliminating bottlenecks is important in the pharmaceutical industry in order to meet the increased demand. Given that the pharmaceutical industry is a growing industry, polymerase chain reaction (PCR) technology has become one of the most valuable technologies used in life sciences, diagnostics and forensics. The development of PCR technology is carried out by several market players and causes strong competition. Due to the high level of competition, it is essential to promote technological development and create optimal production in the pharmaceutical industry in order to meet market demand. It can be expensive to produce reliable equipment in the pharmaceutical industry. To create business goals and analyze improvement opportunities within the production process, optimization systems can be created using simulation. By creating a virtual model, data can be collected to identify problems within the manufacturing industry. With the help of flow simulation, a bottleneck analysis can be created with a focus on waiting times, cycle times and throughput. This study answers the research questions (1) What problems do flow simulations identify when analyzing the performance and bottlenecks of packaging lines in the pharmaceutical industry? (2) What effects does the proposed solution have on the performance of the bottleneck flow in the production process? By simulating different scenarios and identifying problems related to resource usage and priorities at join points, solutions to bottlenecks can be identified. By smoothing priorities and using buffer stocks, companies can create a smoother flow and improve the resilience of their manufacturing systems. The study demonstrates that design and layout choices have a significant effect on total throughput, which emphasizes the importance of careful layout planning and optimization within the pharmaceutical industry. By improving key metrics such as mean time between failure and mean time to repair, companies can increase throughput, productivity and efficiency while achieving financial, ecological, and social sustainability. Recommendation for future studies includes studying the effect of operator location and machine speed on waiting time.

Detta examensarbete är utfört på Scania Södertälje i syftet att kartlägga cykeltider av Kärnamakeri avdelning på nya gjuteriet. Mätning alla av cykeltider för att sen kartläggas görs för att tydligt visualisera utrustnings samt avdelnings kapacitet. Projektet inleddes med insamling av all nödvändig information som underlag för genomförande av arbetet och därefter valdes lämpliga metoder för att uppnå målen. Resultatet visar en berglipig cykeltidskartläggning över hela avdelningen med en tydlig identifiering av flaskhalsarna som styr hela produktionen. Med hjälp av den valda metoden analyserades flaskhalsarna djupnade för att hitta möjliga slöserier i form av onödiga rörelser för att utföra processen. Förbättringsförslag presenterades som avslutning del av projektens resultat samt även som rekommendationer för fortsatt förbättringsarbete att optimera produktionskapacitet. / This thesis project is implemented at Scania Södertälje with the aim of mapping cycle times of the core making department at the new foundry. All measurement of cycle times to then be mapped is done to clearly visualize equipment and department capacity. The project began with the collection of all necessary information as a basis for carrying out the work and then suitable methods were chosen to achieve the goals. The result shows a pronounced cycle time mapping across the entire department with a clear identification of the bottlenecks that control the entire production. Using the chosen method, the bottlenecks were analysed in depth to find possible waste in the form of unnecessary movements to carry out the process. Improvement proposals were presented as a concluding part of the project's results and also as recommendations for continued improvement work to optimize production capacity.

This study was conducted to determine how much time would be saved in the homebuilding cycle when field superintendents received training. The study took place during the 2007 calendar year with a production homebuilder in southern Nevada. New technologies and techniques were introduced during weekly training meetings that were held at both the corporate office and construction job sites. A scheduling tool was introduced along with new procedures and policies. The superintendents were required to report daily on the tasks that had been completed. This gave the superintendent and upper management the ability to follow the home throughout the building process and track the results. Additionally, new policies were created to improve build quality and increase customer satisfaction. This study compared over 300 homes built in 2006 (untrained superintendents) versus nearly 300 homes built in 2007 (trained superintendents). A substantial reduction in cycle time was found when compared to the homes built before the training period, with some projects reducing their average cycle time by over 140 days. Superintendent satisfaction in regards to the training was found to be above average. Through the reduction in cycle time, the company reduced their daily interest costs by nearly 3 million dollars.