Orientador: Messias Borges Silva / Banca: Maurício César Delamaro / Banca: João Batista Turrioni / Resumo: Processos contínuos que utilizam o sistema de produção sob encomenda, como o caso do processo siderúrgico, tem sido pouco abordados como exemplos de implantação da manufatura enxuta por sua pequena similaridade com processos discretos que utilizam o sistema de produção para estoque. Por meio da utilização de práticas e ferramentas enxutas em uma companhia siderúrgica que utiliza o sistema de produção sob encomenda, da análise de seus resultados e de uma pesquisa de campo realizada com gestores de dessa companhia com o objetivo de levantar suas impressões e os resultados alcançados e sobre a eficácia dessas práticas e ferramentas, o trabalho demonstra que a Manufatura Enxuta é aplicável em indústrias siderúrgicas que utilizam sistemas de produção sob encomenda / Abstract: Continuous processes that use the make-to-order (MTO) system, as the case of the make steel process, has been little attention as examples of implementation of lean manufacturing for its similarity to small discrete processes that use the production system of make-to-stock (MTS). Through the use of lean tools and practices in a MTS steel company, of the analysis of their results and a field research with managers of that company in order to raise their views and achievements and the effectiveness of these practices and tools, the work demonstrates that Lean Manufacturing is applicable in steel industries that use MTO production system / Mestre

Submitted by Divisão de Documentação/BC Biblioteca Central (ddbc@ufam.edu.br) on 2017-08-23T15:05:40Z No. of bitstreams: 2 Dissertação - Jean Carlos Sena de Freitas.pdf: 1594563 bytes, checksum: ae3dfa525714fb6165c1593851b89599 (MD5) license_rdf: 0 bytes, checksum: d41d8cd98f00b204e9800998ecf8427e (MD5) / Approved for entry into archive by Divisão de Documentação/BC Biblioteca Central (ddbc@ufam.edu.br) on 2017-08-23T15:05:56Z (GMT) No. of bitstreams: 2 Dissertação - Jean Carlos Sena de Freitas.pdf: 1594563 bytes, checksum: ae3dfa525714fb6165c1593851b89599 (MD5) license_rdf: 0 bytes, checksum: d41d8cd98f00b204e9800998ecf8427e (MD5) / Approved for entry into archive by Divisão de Documentação/BC Biblioteca Central (ddbc@ufam.edu.br) on 2017-08-23T15:06:09Z (GMT) No. of bitstreams: 2 Dissertação - Jean Carlos Sena de Freitas.pdf: 1594563 bytes, checksum: ae3dfa525714fb6165c1593851b89599 (MD5) license_rdf: 0 bytes, checksum: d41d8cd98f00b204e9800998ecf8427e (MD5) / Made available in DSpace on 2017-08-23T15:06:09Z (GMT). No. of bitstreams: 2 Dissertação - Jean Carlos Sena de Freitas.pdf: 1594563 bytes, checksum: ae3dfa525714fb6165c1593851b89599 (MD5) license_rdf: 0 bytes, checksum: d41d8cd98f00b204e9800998ecf8427e (MD5) Previous issue date: 2017-03-30 / With the recent crisis in the brazilian market that has generated a large decline in sales of motorcycles, the market has become increasingly fierce and competitive, forcing companies to improve their skills to make their products more attractive and low-cost, surpassing competitors and offering products that meet customer needs In this context, the research aimed to propose, through the use of software of simulation, improvements in a line of exhaust soldering for motorcycles that allow the reduction of process costs. For this, the mapping of the current value chain was carried out and confirmed by the computational model and then the improvement points were identified and presented in the map of the future value chain. In the improvement proposal, the flow and process stock change was presented. With this, it has been proven that it is possible to reduce inventory, staff and lead time costs. From the results obtained, it was suggested the extension of this research to the rest of the lines of the factory. / Com a recente crise no mercado brasileiro que tem gerado grande retração das vendas de veículos de duas rodas, o mercado tem-se tornado cada vez mais acirrado e competitivo, obrigando empresas a se aperfeiçoarem para tornar seus produtos mais atraentes a baixo custo, superando concorrentes e oferecendo produtos que atendam às necessidades dos clientes. Neste contexto, a pesquisa teve como objetivo propor, mediante a utilização de software de simulação computacional, melhorias em uma linha de solda de escapamento para motocicletas que permitam a redução de custo de processos. (detalhas a metodologia) Para isso, foi realizado o mapeamento da cadeia de valor atual e confirmado pelo modelo computacional e depois identificou-se os pontos de melhorias os quais foram apresentados no mapa da cadeia de valor futuro. Na proposta de melhoria, foi apresentado a mudança do fluxo e estoque de processo. Com isso, provou-se que é possivel reduzir custos com estoques, funcionarios e lead time. A partir dos resultados obtidos, sugeriu-se a extensão desta pesquisa para o resto das linhas da fabrica.

Orientador: Iris Bento da Silva / Dissertação (mestrado profissional) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-19T00:48:39Z (GMT). No. of bitstreams: 1 Azambuja_Renato_M.pdf: 4532092 bytes, checksum: f4ac5caeb5c44a92c458194fa87ea428 (MD5) Previous issue date: 2011 / Resumo: Atualmente, a manufatura enxuta tem sido utilizada como um diferencial competitivo pelas indústrias automobilísticas. O objetivo deste trabalho é a aplicação das ferramentas, conceitos e metodologias do sistema de manufatura enxuta numa linha de montagem de motores diesel pelos próprios trabalhadores de chão-de-fábrica a partir da disseminação do conhecimento sobre o tema. O método pesquisa-ação será utilizado para o desenvolvimento deste estudo, a fim de se propor melhorias no ambiente produtivo por meio da aplicação dos conhecimentos adquiridos pelos trabalhadores em um sistema de manufatura enxuta, visando maior produtividade, menor custo, menor desperdício, ganho de qualidade, melhor organização, proporcionando mudanças no ambiente de trabalho que contribuam para a agregação de valor nas atividades dos trabalhadores envolvidos / Abstract: Currently, the lean manufacturing has been used as a competitive differential for the automobile companies. The objective of this work is the application of the tools, concepts and methodologies of the lean manufacturing in a diesel engine assembly line by the proper workers through the dissemination of the knowledge about the subject. The method research-action will be used for the development of this study, in order to consider improvements in the productive environment by means of the knowledge application acquired for the workers in a lean manufacturing system, aiming at more productivity, less cost, less wastefulness, increase of quality, better organization, providing changes in the work environment that contribute for the value's aggregation in the worker's activities / Mestrado / Manufatura / Mestre em Engenharia Automobilistica

Made available in DSpace on 2014-06-12T17:42:15Z (GMT). No. of bitstreams: 2 arquivo7415_1.pdf: 952084 bytes, checksum: 4201f7167555c4278aaad41e10ddc4a7 (MD5) license.txt: 1748 bytes, checksum: 8a4605be74aa9ea9d79846c1fba20a33 (MD5) Previous issue date: 2004 / Atualmente as empresas encontram-se inseridas em mercados marcados por diversas transformações nas características de consumo. Desta forma, as empresas tentam adequar-se ao ambiente de constante transformação substituindo o paradigma da produção em massa pelo da flexibilidade. Os resultados e o crescimento obtidos pelas empresas orientais nas últimas décadas, particularmente da Toyota Motors Company, despertaram as empresas ocidentais para esta mudança de cenário. Desde então, estas empresas começaram a implementar as técnicas e os conceitos da Produção Enxuta (no original, Lean Manufacturing). No entanto, poucas empresas conseguem romper verdadeiramente os tradicionais paradigmas da produção em massa. Entre os diversos problemas enfrentados durante um processo de implementação da Produção Enxuta, destaca-se a falta da formulação de um conjunto de medidas de desempenho que permitam aos gestores, gerir com adequada eficiência e eficácia as ações de implementação desta nova lógica produtiva. O acompanhamento deste período de transição precisa ser norteado por um conjunto de indicadores de desempenho que possibilitem a devida motivação e orientação dos recursos envolvidos. Desta forma, optou-se por utilizar a metodologia do Balanced Scorecard, pois esta permite o acompanhamento do desempenho financeiro, através de relações de causa e efeito, em objetivos em diferentes perspectivas de uma empresa (cliente, processos internos e aprendizado e crescimento). O modelo construído foi aplicado em uma empresa calçadista de grande porte em fase inicial de implementação da Produção Enxuta. O modelo proposto culminou em resultados que representaram adequadamente as dificuldades e os benefícios obtidos com o advento da Produção Enxuta

M.Phil. (Leadership, Performance & Change) / *Orientation - More and more South African organisations are turning to prominent productivity improvement systems such as Lean Production (LP). Sustaining LP, however, requires the creation of a discernible management system. One of the perennial questions in LP is whether a management system with such a strong Japanese orientation can be successfully transplanted into a heterogeneous culture such as South Africa. * Research purpose - This research aimed to investigate whether the behaviours and values adopted by successful middle managers in supporting a sustainable LP management system differ from those identified by Van Dun (2008) in a comparative study conducted in the Netherlands. The research also aimed to establish whether managers from different ethnic groups in South Africa adopt different behaviours and values. * Motivation for the study – Identifying the behaviours and values of LP middle managers in the context of both national and sub-cultures will assist in making the necessary allowances in order to limit dissonance and strengthen LP transformation. * Research design, approach and method – The study was conducted in two phases. Firstly, a two round Delphi-study was undertaken to identify criteria for the identification of successful LP middle managers, and to ensure that the Behavioural Leadership Questionnaire developed in the Netherlands has theoretical equivalence in South Africa. During the second phase, successful LP managers, their immediate superiors, subordinates and internal LP practitioners were surveyed in order to identify the extent to which certain LP behaviours and values were demonstrated. The data from the survey was analysed using parametric and comparative statistics. * Main findings – The results indicate that altough LP behaviours and values appear universal, these behaviours and values are to a large extent influenced by national culture. Cross-cultural influences based on racial demographics in South Africa is however inconsequential.

James Womack and his colleagues Daniel Jones and Daniel Roos changed the way western civilization approached manufacturing. In 1990, they published a book called ‘The Machine That Changed the World: The Story of Lean Production’. It was a concept that had slowly filtered from the east but had not made its mark on the manufacturing sector. The concept of lean, born out of the Japanese Toyota Manufacturing System, was first thought to be impossible to duplicate outside of Japan. Since Womack and company popularised this “new” way of producing goods and delivering services it spread across industries finding popularity in the medical, engineering, accounting and especially the manufacturing industries. Over the last few decades lean practices has been synonymous with efficiency, cost reduction, supply chain optimisation and innovative problem solving (Anvari Norzima, Rosnah, Hojjati and Ismail, 2010; Pieterse et al., 2010; Womack et al., 1990). Lean process implementation has been researched in abundance, as has failed attempts at lean implementation. The purpose of this study was to identify and assess enablers of lean sustainability in organisations where lean processes are already being implemented. The literature study found Organisational Culture, Leadership, Employee Engagement and Trade Unions participation as factors that contributed to successful lean implementations. The author developed a model to test Organisational Culture, Leadership, Employee Engagement and Trade Unions as enablers to sustain lean practices in organisations in South Africa’s manufacturing industries. The results proved that Organisational Culture, Leadership and Employee Engagement were considered enablers for lean sustainability. These three enablers have an interlinked relationship and together help sustainability. Lacking just one factor would surely result in unsustainable lean practices. The study was conducted in the quantitative paradigm, as the hypothesised relationship was statistically tested. The data was collected from a homogenous group via an email sent with a link to the questionnaire. The data was statistically analysed with Statistica software and Microsoft Excel.

The automotive components manufacturing sector is facing tremendous pressure to remain competitive in a global economy. The application of performance improvement techniques to optimise factor production inputs remains a key strategic mechanism to effect the necessary change towards competitiveness. The high failure rate of these programmes, however, is a risk factor that should be considered by manufacturing firms. The investment into the implementation of these programmes will yield no return if the organisational maturity profile is not considered. The expected gains may not materialise and the execution of critical projects may take much longer than required. It is for this reason that an approach towards selecting the correct Performance Improvement Programme to optimise the performance of companies is a business imperative. Through a better understanding of the relationships between Performance Improvement Programmes and Organisational Maturity Variables, implementation success rates can increase, leading to improved results and sustainability. The approach taken to this research was quantitative in nature. Various descriptive and inferential statistics were applied to the selected respondents from the Eastern Cape automotive sector. The respondents had a working knowledge of Lean Manufacturing, Total Productive Maintenance (TPM) and Six Sigma. The research instrument was administered through an online survey. The research sought to identify whether there was a relationship amongst the variables under the three identified constructs. The research also sought to establish whether there was a difference between the specific Performance Improvement Programmes’ and Organisational Maturity Variables’ relationships. This affirmed the use of a new framework that integrates the programmes on the basis of their relationship to Organisational Maturity Variables. The research also provided insight into the challenges of the industry from a performance perspective and linked these with the relationship between Organisational Maturity Variables and Organisational Performance Variables. This allowed the researcher to include this additional insight as a consideration in the integrated implementation framework developed as part of the research. The results show that good consideration should be given to the Organisational Maturity Variables as these variables are related to the successful adoption of Performance Improvement Programmes. The research also shows that Lean Manufacturing, Total Productive Maintenance and Six Sigma are related to an organisations’ maturity profile in different ways. These results support the integrated Performance Improvement Programme approach, using a common set of tools and selecting the necessary programme specific tools based on a firm’s maturity profile. The research affords industry a framework to aid in decision making considering the relationships tested as part of this research. The linkages between Performance Programmes, Organisational Maturity Variables and Organisational Performance Variables are now more specific in nature.

This study aimed to identify the causes of significant problems existing in the metallurgical sector, and a solution is proposed for the setup process. We detail the theoretical background of the processes in the lean manufacturing methodology, which will be applied to a rolling machine. Further, we provide a brief description of the company and the sector’s problems. We describe success stories of companies that implemented various lean manufacturing tools. We also present some of the results achieved across sectors to gain an in-depth understanding of the technique and a practical support of the implemented model. Our proposal is based on the lean manufacturing methodology; tools such as Single Minute Exchanges of Dies, Kaizen, 5S, and value stream mapping (VSM) will be used to reduce setup times and to impact machine layout and productivity positively. We also show the implementation results of a pilot plan conducted in the company over a period of more than 3 months. / Revisión por pares

Esta tesis tiene por finalidad elaborar una propuesta de mejora en gestión de mantenimiento en uno de los Centro Comerciales más importantes del país, el objetivo es de incrementar el porcentaje de condición de operatividad a 97% de los sistemas de ingeniería que se maneja (hidráulica, montacargas y escaleras eléctricas, eléctrico, aire acondicionado, red contra incendio y sanitario) que actualmente están en 94% en promedio. El primer capítulo contiene artículos de investigación referentes a la propuesta de mejora con evidencias de empresas que tuvieron éxitos aplicando metodología Lean y herramientas como TPM, con la aplicación de las hojas FMEA. El segundo capítulo se enfoca en diagnosticar los problemas de operatividad de los sistemas, teniendo en cuenta la condición de operatividad que se maneja, además se identificará y priorizará las causas de los principales problemas teniendo en cuenta los sistemas con mayor costo de mantenimiento correctivos no programados, sobre los cuales se aplicará propuestas de mejora. El tercer capítulo se desarrollará las propuestas de mejora para reducir los trabajos de mantenimiento correctivo no programado y mejorar la condición de operatividad de los sistemas, mediante la introducción de la hoja FMEA y con el apoyo del equipo formado con los técnicos operarios. Finalmente se presentarán conclusiones y recomendaciones las cuales darán a conocer el ahorro y el tiempo de recupero de la propuesta. / This project aims to develop a proposal for improvement in maintenance management in one of the most important Commercial Centers in the country, the objective is to increase the percentage of operational condition to 97% of the engineering systems that are managed (hydraulic, elevators and escalators, electric, air conditioning, fire network and sanitary) that are currently at 94% on average. The first chapter contains research articles referring to the improvement proposal with evidence of companies that had success applying Lean methodology and tools such as TPM, with the application of FMEA sheets. The second chapter focuses on diagnosing the problems of operation of the systems, taking into account the operating condition that is handled, in addition the causes of the main problems will be identified and prioritized taking into account the systems with the highest unscheduled corrective maintenance costs , on which improvement proposals will be applied. The third chapter will develop improvement proposals to reduce the unscheduled corrective maintenance work and improve the operating condition of the systems, by introducing the FMEA sheet and with the support of the team formed with the operating technicians. Finally, conclusions and recommendations will be presented which will make the savings and recovery time of the proposal known. / Trabajo de Suficiencia Profesional

En el presente artículo se aborda la problemática de la baja eficiencia de un proceso productivo en una empresa manufacturera. Esta investigación busca integrar y modelar diferentes herramientas de la ingeniería, con un modelo más eficiente que evite costos altos de mantenimiento de los equipos de producción, sin incurrir en elevados costos por implementación. En tal sentido, este artículo presenta un Modelo de Reducción de Desperdicios que busca reducir el tiempo de set up y desarrollar una gestión del mantenimiento adecuada para lograr el incremento de la Eficiencia General de los Equipos (OEE). La validación del modelo ha sido realizada en una empresa de manufactura de neumáticos en el Perú y arrojó resultados positivos tales como un incremento del OEE de 13%, una reducción de tiempos de set up de 22.5% y como consecuencia un incremento en la capacidad de cambios de componentes, la externalización de 37 actividades y un incremento del 80% en el índice de conocimiento de los operarios involucrados en la propuesta. / This article addresses the problem of low efficiency of a production process in a manufacturing company. This research seeks to integrate and model different engineering tools, with a more efficient model that avoids high maintenance costs of production equipment, without incurring high costs for implementation. In this regard, this article presents a Waste Reduction Model that seeks to reduce set-up time and develop proper maintenance management to achieve the increase in General Equipment Efficiency (OEE). The validation of the model has been carried out in a tire manufacturing company in Peru and yielded positive results such as an OEE increase of 13%, a set-up time reduction of 22.5% and as a consequence an increase in the capacity of component changes, the transformation of 37 activities from internal to external and an 80% increase in the knowledge index of the operators involved in the proposal. / Tesis