Submitted by Fabio Medeiros (medeirosfb@hotmail.com) on 2018-08-29T19:18:50Z No. of bitstreams: 1 DissertaçãoOficial_FabioMedeiros_Final_2018-07-13.pdf: 1886756 bytes, checksum: 97237a802cf505a292bc9315360ed503 (MD5) / Approved for entry into archive by Mayara Costa de Sousa (mayara.sousa@fgv.br) on 2018-09-05T18:08:23Z (GMT) No. of bitstreams: 1 DissertaçãoOficial_FabioMedeiros_Final_2018-07-13.pdf: 1886756 bytes, checksum: 97237a802cf505a292bc9315360ed503 (MD5) / Approved for entry into archive by Suzane Guimarães (suzane.guimaraes@fgv.br) on 2018-09-06T12:15:47Z (GMT) No. of bitstreams: 1 DissertaçãoOficial_FabioMedeiros_Final_2018-07-13.pdf: 1886756 bytes, checksum: 97237a802cf505a292bc9315360ed503 (MD5) / Made available in DSpace on 2018-09-06T12:15:47Z (GMT). No. of bitstreams: 1 DissertaçãoOficial_FabioMedeiros_Final_2018-07-13.pdf: 1886756 bytes, checksum: 97237a802cf505a292bc9315360ed503 (MD5) Previous issue date: 2018-07-04 / As grandes corporações têm intensificado a otimização de suas redes logísticas, entendendo a importância estratégica que a área de operações possui, não somente em relação a liberação de recursos através de redução de custos, mas também na geração de valor através dos serviços prestados a seus clientes. Este movimento trouxe consigo um amplo desenvolvimento tecnológico para as operações de distribuição e logística. No que diz respeito a automação, existe uma evolução significativa, principalmente nos processos internos dos centros de distribuição, tais como: sistemas inteligentes de guarda e retirada de produtos, operações de empilhadeiras sem tripulação humana, carregamento e descarregamento mecanizado de caminhões, sistemas automatizados de separação de pedidos e máquinas para montagem e fechamento de caixas, entre outros exemplos. No entanto, não há uma grande variedade de estudos de casos sobre operações, já automatizadas, que elevaram seus níveis de produtividade e qualidade significativamente, sem investimentos de capital, mas através de redesenho de processos e atuação das lideranças operacionais. Este trabalho, portanto, tem como objetivo capturar e demonstrar o que foi realizado para se obter ganhos significativos em produtividade e qualidade nas operações logísticas através desta união: ferramentas de melhoria contínua e atuação das lideranças, sem o uso de investimentos de capital. O problema de pesquisa está focado, então, em capturar e demonstrar as iniciativas implementadas durante a transformação pela qual o processo de distribuição da empresa passou em relação as suas atividades logísticas, bem como as ferramentas de melhoria contínua utilizadas. Para tanto, foi realizada uma pesquisa do tipo estudo de caso da operação logística da Avon Cosméticos no Brasil, entre os anos de 2015 a 2017, que passou por este processo de transformação. Como resultado, espera-se detalhar estes projetos e iniciativas implementados bem como as metodologias ou ferramentas aplicadas, as melhorias obtidas e a conexão entre teoria e prática. Como aporte deste trabalho, espera-se reforçar a teoria existente sobre melhoria contínua de processos, contribuindo assim com os mundos acadêmico e empresarial no que diz respeito a otimização de operações. / Large corporations have intensified the optimization of their logistics networks, understanding the strategic importance that the operations area has not only related to the resources release through cost reduction, but also in value generation through the services provided to its customers. This movement brought with it a broad technological development for distribution and logistics operations. As far as automation is concerned, there is a significant evolution, especially in the internal processes of distribution centers, such as: intelligent systems for guarding and withdrawing products, forklift operations without human crew, mechanized loading and unloading of trucks, automated separation of orders and machines for assembly and boxes closing, among other examples. However, there is not a wide range of case studies on operations, which are already automated, that have raised their levels of productivity and quality significantly, without capital investments, but through processes redesign and the performance of operational leadership. This work, therefore, aims to capture and demonstrate what has been done to achieve significant gains in productivity and quality in logistics operations through this union: tools for continuous improvement and leadership performance, without significant use of capital capex. The research problem is then focused on capturing and demonstrating implemented initiatives during the transformation by which this company's distribution process passed related to its logistic activities, as well as the continuous improvement tools used. To do so, a case-study of the logistics operations of Avon Cosmetics in Brazil, between the years of 2015 and 2017, was carried out. As a result, it is expected to detail these projects and initiatives implemented as well as the methodologies or tools applied, the improvements obtained and the connection between theory and practice. As a contribution of this work, it is hoped to reinforce the existing theory on continuous process improvement, thus contributing to the academic and business worlds regarding to operations optimization.

O objetivo geral deste trabalho é estudar em uma indústria automotiva a redução dos custos de refugos e retrabalhos causados por não qualidade de fabricação ou devido a anomalias nos transportes das peças compradas de fornecedores da Europa. Para a obtenção dos resultados, o método utilizado inicialmente foi a pesquisa bibliográfica fornecendo a base para o estudo de caso descritivo em uma indústria automotiva. Este trabalho teve como finalidade a pesquisa aplicada, pois foi motivada pela resolução de um problema concreto, que é a redução destes custos. Inspirado nas ferramentas da Manufatura Enxuta foi criado um grupo de trabalho para elaborar um procedimento de re-faturamento dos custos de não qualidade dos fornecedores da Europa e aplicado a metodologia Hoshin para a melhoria nos processos da seguradora em caso de sinistros nos transportes destes fornecedores. Para resolver estes problemas as ferramentas da qualidade foram amplamente utilizadas. Foi possível re-faturar os fornecedores Externos da Europa em cerca de R$ 635.000,00 e reduzir R$ 305.312,00 de custos com refugos dos Fornecedores Internos da Europa. A aplicação do procedimento estimulou os Fornecedores Internos e Externos e o custo mensal com refugos considerando o re-faturamento passou de R$ 86.973,00 para R$ 10.104,00. O custo por veículo foi de R$ 10,32 para R$ 3,74. O ganho total somado até 2009 foi de R$ 1.238.476,00. / The general purpose of this work is to study, in an automotive industry, the reduction of the costs of scrap and rework caused by no manufacturing quality or due to deficiencies in transport parts purchased from suppliers in Europe. To obtain the results the method was initially used to search bibliographic providing the basis for the descriptive case study in an automotive industry. This study was aimed at applied research, because it was motivated by solving a real problem, which is the reduction of these costs. Inspired by the tools of Lean Manufacturing it was created a working group to develop a procedure for invoicing again the not quality costs from European suppliers as well as the methodology was applied Hoshin to improve the processes of insurer in case of accidents in transport of these suppliers. To solve these problems the quality tools have been widely used. It was possible to invoice again from external suppliers in Europe about R$ 635.000,00 and lower R$ 305.312,00 in costs with scraps of domestic suppliers in Europe. Applying the procedure prompted the internal and external suppliers and the monthly cost with scrap considering the re-sales rose from R$ 86.973,00 to R$ 10.104,00. The cost per vehicle was R$ 10,32 to R$ 3,74. The gain added by 2009 was R$ 1.238.476,00.

La investigación está orientada al diseño e implementación de un Modelo Integrado de Gestión de la Producción para la fabricación de llaves de cerradura, este modelo integra la teoría de restricciones para resolver los cuellos de botella y utiliza algunas herramientas de Lean Manufacturing para eliminar los desperdicios que se generan en los procesos que generan los cuellos de botella. El objetivo de la aplicación del modelo es el mejorar la productividad de la línea de fabricación de llaves de cerradura, la reducción de costos mediante la mejora de la eficiencia de sus procesos que permitan a la empresa ser más competitiva en el mercado. The research is focused on the design and implementation of an integrated management of production for the manufacture of keys lock model, this model integrates the theory of constraints to solve bottlenecks and used some tools of lean manufacturing to eliminate waste that is generated in the processes that create bottlenecks. The purpose of applying the model is to improve the productivity of the manufacturing line lock keys, reducing costs by improving the efficiency of their processes that enable the company to be more competitive in the market.

Les systèmes assemble-to-order (ATO) peuvent être considérés comme une affectation de ressources multiples qui induit planification de production, satisfaction des contraintes et affectation des stocks. Les systèmes ATO représentent une stratégie de logistique populaire utilisée en gestion de fabrication. En raison de la complexité croissante des systèmes de fabrication d'aujourd'hui, le défi pour les systèmes ATO est de gérer efficacement les stocks de composants et de trouver les décisions optimales de production et d'affectation.Nous étudions un système ATO avec un produit unique qui est assemblé à partir de plusieurs composants. Le système doit répondre à une demande non seulement du produit assemblé, mais aussi des composants individuels. Nous considérons le cas avec seulement des lost sales puis le cas mixte lost sales et backorders avec des temps de production suivant des lois de type exponentiel et une demande sous forme de loi de Poisson. Nous formulons le problème comme un Processus de décision markovien (MDP), et nous considérons deux critères d'optimalité qui sont le coût actualisé et le coût moyen par période. Nous caractérisons la structure de la politique optimale et étudions l'impact des différents paramètres du système sur cette politique. Nous présentons également plusieurs heuristiques pour le cas lost sales et le cas mixte lost sales et backorders. Ces heuristiques fournissent des méthodes simples, mais efficaces pour contrôler la production et l’affectation des stocks du système ATO / Assemble-to-order (ATO) systems can be regarded as a multiple resource allocation that induces production planning, requirements fulfilling and inventory assignment. ATO is a popular strategy used in manufacturing management. Due to the increasing complexity of today’s manufacturing systems, the challenge for ATO systems is to efficiently manage component inventories and make optimal production and allocation decisions. We study an ATO system with a single product which is assembled from multiple components. The system faces demand not only from the assembled product but also from the individual components. We consider the pure lost sales case and the mixed lost sales and backorders case with exponential production times and Poisson demand. We formulate the problem as a Markov decision process (MDP), and consider it under two optimality criteria: discounted cost and average cost per period. We characterize the structure of the optimal policy and investigate the impact of different system parameters on the optimal policy. We also present several static heuristic policies for the pure lost sales and the mixed lost sales and backorders cases. These static heuristics provide simple, yet effective approaches for controlling production and inventory allocation of ATO system

The aim of the master’s thesis is analysis of practical application limits of waste-gate TwinScroll turbocharger located in BMW X6 M vehicle by using DFSS (Design For Six Sigma) tools. The goal is to create a special measurement device for a measurement of waste gate leakage with chance of testing all sorts of characteristics having impact on key parameters of turbocharger.

The world has become more competitive, complex and unpredictable, and this process is continuing. Evolution is taking place resulting in organisations being pushed by strategies and pulled by increasingly assertive customers who demand more accountability and responsiveness (Kartte, 2010). In order to remain competitive in this changing world, many organisations, even financial institutions have adopted Lean principles in order to eliminate waste, reduce cost and streamline everyday processes (Spear, 2012). There have however been a number of challenges that have prevented financial institutions from implementing Lean principles successfully. The primary objective of this study is to improve the effectiveness of Lean principles within a specific financial institution. More specifically, this study will identify the effectiveness of successfully implementing Lean principles at a financial institution by investigating the influence of employee knowledge, understanding and skills, communication, motivation and ownership from management, organisational culture and the impact of trade unions in organisations as mentioned in the problem statement above. Convenience sampling was used to select a sample of sixty eight (68) employees within the specific financial institution. The sample was stratified to include senior managers, managers, team leaders and lower level employees. Questionnaires were distributed personally to the focus groups from the above categories.

Les travaux de cette thèse sont articulés autour du problème d’ordonnancement de tâches dans un type d’atelier de structure complexe peu étudié dans la littérature. Cet atelier est de composition hybride : chaque étage de l’atelier a une ou plusieurs machines. Les principales contraintes considérées sont le traitement par lots et la minimisation du retard total. Les méthodes de résolution de ce problème sont intégrées dans les systèmes d’aide à la décision du programme de recherche du Groupe SouffletEtant donné la structure complexe du type d’atelier considéré, nous avons décomposé ce dernier afin d’étudier plus particulièrement le problème d’ordonnancement sur machines parallèles identiques. Différentes méthodes de résolution sont testées. Les résultats sont analysés afin de proposer une classification d’instances et de méthodes de résolution. Les problèmes étudiés sont résolus de manière exacte et approchée. Différentes méthodes ont été testées : des recherches itératives, des algorithmes tabous, des méthodes évolutionnaires. Les conclusions de la résolution du problème d’ordonnancement des machines parallèles sont utilisées pour construire des méthodes à deux niveaux pour le problème complexe d’ordonnancement. Les résultats montrent que les algorithmes trouvent des solutions de bonne qualité pour le problème traité. De la même manière, de problématiques industrielles similaires sont traitées, dans l’objectif d’optimiser le fonctionnement du centre de recherche / This thesis considers a complex workshop scheduling problem, which is rarely studied to our knowledge. This workshop has a hybrid composition : one or several machines are available at each stage. Main considered constraints are batch processing and total tardiness minimization. Solution methods are embedded on the information system of research program of Soufflet Group. Given the complex structure of the workshop, it has been split in order to study the parallel machines scheduling problem individually. Different solution methods are developed. Obtained results are used to build a classification of instances and solution methods. To solve described problems, exact and approach solution methods are proposed. We have adapted iterated search, tabu search, genetic algorithms, … Findings from solving parallel machines scheduling problem are employed to develop a two levels solution method for the described flow shop problem. Results show the performance of developed algorithms to find good quality solutions for described scheduling problem. Similarly, industrial problems are considered, in order to optimize operational behavior of research center

Hoy en día, las organizaciones industriales enfocados en la confección de prendas algodón buscan incrementar su competitividad a través de actividades que generen valor agregado a los productos. Por ello, el objetivo de este artículo es mejorar el proceso de cortado de tela de las mypes exportadoras de prendas de algodón mediante la identificación y eliminación de desperdicios, definidos como procesos o actividades que no agregan valor, específicamente en el área de corte de una empresa textil. Además, esta mejora se dará bajo la aplicación de la filosofía Lean Manufacturing a través de las herramientas del VSM, SMED y estandarización de trabajo, el cual se respalda mediante un análisis de datos, validación económica y simulación mediante el uso de los datos históricos de la empresa en estudio. Asimismo, a través del estudio realizado se logró reducir los reprocesos por defecto de 13.12% a 4.23%, los procesos con demora se han reducido de 18.49 a 9.61% y el índice de productividad del área de corte se incrementó de 0.38 a 1.16. / Today, industrial organizations focused on making cotton garments seek to increase their competitiveness through activities that generate added value to products. Therefore, the objective of this article is to improve the fabric cutting process of cotton garment exporting mypes by identifying and eliminating waste, defined as processes or activities that do not add value, specifically in the cutting area of ​​a textile business. In addition, this improvement will occur under the application of the Lean Manufacturing philosophy through the VSM, SMED and work standardization tools, which is supported by data analysis, economic validation and simulation through the use of historical data from the company under study. Likewise, through the study carried out, it was possible to reduce the default reprocesses from 13.12% to 4.23%, the processes with delay have been reduced from 18.49 to 9.61% and the productivity index of the cutting area increased from 0.38 to 1.16. / Trabajo de investigación

Actualmente, las empresas de alimentos en el Perú presentan una serie de deficiencias internas que contribuyen a la aparición de problemas críticos, como es el caso de los productos defectuosos. Por ello, la presente investigación propone un modelo de mejora para reducir el índice de defectos en la fabricación de productos alimenticios, mediante la estandarización del trabajo y la aplicación de herramientas del TPM. Asimismo, este modelo es desarrollado bajo un enfoque de Gestión del Cambio, con el fin de eliminar la resistencia de los trabajadores frente al cambio en su cultura laboral. La efectividad del modelo fue validada mediante una simulación con el Software Arena, obteniendo como principal resultado la reducción del porcentaje de defectos de 23.5% a 12.5%, en la empresa del caso de estudio. Esto permite concluir que el desarrollo de la propuesta mejora la calidad de la producción, lo que a su vez representa una oportunidad para obtener mayores ingresos para la empresa. / Currently, food companies in Peru have a series of internal deficiencies that contribute to the appearance of critical problems, such is the case of the defective products. Therefore, this research proposes an improvement model to reduce the rate of defects in the manufacture of food products, through the standardization of work and application of TPM tools. Likewise, this model is developed under a Change Management approach, in order to eliminate the resistance of the workers against the change in their work culture. The effectiveness of the model was validated through a simulation with the Software Arena, obtaining as the main result the reduction of the percentage of defects from 23.5% to 12.5%, in the company of the case study. This allows to conclude that the development of the proposal improve the quality of production, which in turn represents an opportunity to obtain higher income for the company. / Trabajo de investigación

Este artículo de investigación analiza los antecedentes y problemas actuales que presentan las empresas del sector plástico por la prohibición en la fabricación, distribución y utilización de bolsas convencionales, debido a las diversas disposiciones establecidas por el Estado. Y a su vez los problemas internos de producción que se han identificado en la empresa de estudio, tales como la parada de máquinas y el inadecuado uso del personal, generando así la existencia de mermas y tiempos improductivos en la fabricación de bolsas plásticas. Por lo cual, se propone un Modelo de Producción Lean Manufacturing mediante un enfoque Biotecnológico para una empresa Mype del Sector Plástico. En donde, se utilizará técnicas de solución como la metodología 5S, la Gestión por Procesos y la Biotecnología, que consiste en utilizar recursos naturales como materia prima fundamental para producir un producto eficiente y adecuado, las cuales fueron analizadas y aplicadas en la revisión de la literatura. Como principal resultado de esta propuesta se obtendrá una producción eficiente de bolsas biodegradables, como alternativa de sustitución al plástico convencional. Finalmente, se realizará una validación por simulación para evidenciar las mejoras presentadas en la empresa. Es importante señalar que como principal conclusión se tiene obtener un producto innovador que garantice una viabilidad económica, social y medioambiental en los negocios del sector plástico. / This research article analyzes the antecedents and current problems that companies in the plastic sector present due to the prohibition on the manufacture, distribution and use of conventional bags, due to the various provisions established by the State. And in turn, the internal production problems that have been identified in the study company, such as the stoppage of machines and the inappropriate use of personnel, thus generating the existence of wastage and unproductive times in the manufacture of plastic bags. Therefore, a Lean Manufacturing Production Model is proposed through a Biotechnological approach for a Mype company in the Plastic Sector. Where, solution techniques such as the 5S methodology, Process Management and Biotechnology will be used, which consists of using natural resources as fundamental raw material to produce an efficient and adequate product, which were analyzed and applied in the review of the literature. The main result of this proposal will be an efficient production of biodegradable bags, as an alternative to conventional plastic. Finally, a simulation validation will be carried out to show the improvements presented in the company. It is important to note that the main conclusion is to obtain an innovative product that guarantees economic, social and environmental viability in business in the plastics sector. / Trabajo de investigación