Orientador: Daniel Jugend / Co-orientador: Renato Campos / Banca: Rosane Aparecida Gomes Battistelle / Banca: Assed Naked Haddad / Resumo: A utilização dos princípios da Lean Construction como estratégia de melhorias em canteiros de obra, vem crescendo diariamente. Este trabalho tem como objetivo identificar com base numa revisão sistemática na literatura nacional, a relação da utilização de princípios e ferramentas da Lean Construction e contribuição no processo de melhorias em canteiros de obra. Os objetivos secundários delimitaram-se em levantar aplicação dos princípios da Lean Construction, avaliar a relação da utilização dos princípios e ferramentas e sua contribuição no processo de melhoria em canteiros de obras e identificar a produção científica relacionada à Lean Construction. A partir do questionamento de como está sendo conduzido o tema na literatura e qual a sua relação entre a utilização de princípios e ferramentas da Lean Construction e sua contribuição no processo de melhorias em canteiros de obr, o trabalho possibilitou respondê-los, principalmente numa qualificação das publicações sobre o tema na pesquisa naciuonal. A conclusão da pesquisa traz resultados como: a ferramenta computacional BIM (Building Information Modelling) foi a ferramenta mais estudada entre os artigos nos últimos 5 anos, 80% dos autores não citam o porte da empresa sendo P (pequena), M (média) e G (grande), houve um avanço nas publicações sobre Lean Construction entre os anos de 2011-2014, abordagem científica, 80% dos artigos referem-se a aplicação prática e 20% são de aplicação teórica, incidiu maior número de publicações que utilizam os princípios: introduzir melhorias contínuas nos processos e aumentar a transparência do processo com 27% das publicações. O conceito dos princípios da Lean Construction versus a ferramenta utilizada está sendo pouco explorado no âmbito da pesquisa científica, justificando assim avançar com discussão do tema. Cita-se o período de tempo referente às principais publicações nacionais... / Abstract: The use of the principles of Lean Construction as a strategy to improvements in construction sites, is growing dailiy. This work aims to identify based on a systematic review in the national literature, the utilization ratio of principles and tools of Lean Construction and contribution in the process of improvements in construction sites. Secondary objectives delimed on raising applying the principles of Lean Construction, evaluate the utilization ratio of the principles and tools and their contribution in the improvements process on construction sites and identify the scientific production related to Lean Construction. From the question of how the issue is being conducted in the literature and what is the relationship between the use of principles and tools of Lean Construction and its contribution in the process of improvements in construction sites, work possible answer them especially in a qualification of publications on the subject in national surveys. The conslusion of the research brings results as a computational tools BIM (Building Information Modelling) was the most studied tools between the articles in the last five years, 80% of authors did not mention the size of the company being P (small), M (medium) and L (large), there was a breathrough in publications on Lean Construction between the years 2011-2014, scientific approach, 80% of the articles relate to the practical application and 20% of theoretical application, focused highest number of publications that use principles: to introduce continuous improvements in processes and increase transparency of the process with 27% of the publications. The concept of the principles of Lean Construction verus the tool used being little explored in the scientific research, thus justifying proceed with discussion on the subject. Read the time referring to the main national publications, generating some volume of production in the area. Another example is the difficulty the academic... / Mestre

Orientador: Edgard Dias Batista Junior / Banca: Guilherme Ari Plonski / Banca: Piotr Trzésniak / Banca: Ana Cristina Limongi França / Banca: Geilson Loureiro / Resumo: Na procura por melhor competitividade, a indústria automotiva tem discutido e aplicado diversos conceitos relacionados a pessoas e processos. Todavia, em muitas organizações, os conceitos adotados são implementados e mantidos de forma desarticulada. Nesse contexto, diversos autores reconhecem o papel da vantagem competitiva do conhecimento, o qual é tratado de forma implícita nos modelos tradicionais de Gestão da Produção. Explorando oportunidades neste cenário, esta Tese apresenta um modelo de Gestão da Produção (MGP-C) que integra os conceitos de Gestão do Conhecimento, Organização do Trabalho e Organização da Produção. Para a realização desta Tese, o escopo da pesquisa foi delimitado ao ambiente operário da indústria automotiva. A escolha do setor automotivo é justificada devido a sua importância econômica e a sua identidade com os paradigmas industriais estudados nesta pesquisa, a manufatura enxuta e em massa, e os grupos enriquecidos e semi-autônomos. Focada em linhas de montagem, devido a sua característica de complexidade de controle do trabalho das pessoas e sua influência na produção. O MGP-C foi construído com enfoque empíricodescritivo e é caracterizado como conceitual, sendo considerado uma base para a construção de ferramentas para diagnóstico ou prescrição de ações operacionais para a Gestão de Produção. O MGP-C alarga os marcos conceituais verificados na pesquisa bibliográfica a partir da integração de fatores alavancadores da Gestão do Conhecimento com os da Organização do Trabalho e os da Produção e torna explícito o uso do tema conhecimento. Desta forma ele contribui à promoção de um contexto favorável à criação e ao compartilhamento do conhecimento pelas pessoas do ambiente operário, e fomenta à inovação incremental. / Abstract: In search for better competitiveness, the automotive industry has discussed and applied several concepts related to people and processes. However, in many organizations, the adopted concepts are implemented and kept unarticulated. In this context, authors recognize the role of the knowledge as competitive advantage, but it is still dealt in an implicit way with the traditional models of Production Management. Exploring opportunities in this scenario, this Thesis aims to present a Production Management Model that integrates the concepts of Knowledge Management, Work Organization and Production Organization. For the realization of the present Thesis, the scope of the research was restricted to be the labour environment of the autoparts plants shopfloor. The choice of the automotive sector is justified due to its economic significance and identity with the industrial paradigms studied in this research, lean and mass production, enriched and semi-autonomous groups. The research focus on assembly line process was due to its characteristic of complexity of the "control" of people work and to its influence on the production. The proposed Model was built using an empirical-descriptive approach and is characterized as conceptual; therefore, it can be considered as baseline to tools for diagnosis or prescription of operational actions for Production Management. The proposed Model widens conceptual landmarks verified in the literature research while it integrates the factors of Knowledge Management to the ones of Work and Production Organization and it makes explicit the use of the theme knowledge. This contributes to promote of a favourable context for the creation and sharing of knowledge, among the people in the labour environment, and to support incremental innovation. / Doutor

Este trabalho busca apresentar um modelo de análise e projeto de layout industrial para empresas que estão implantando ou já implantaram os conceitos da Produção Enxuta. O modelo desenvolvido foca empresas de manufatura discreta em ambientes com uma alta variedade de produtos. O desenvolvimento do modelo foi elaborado com base na literatura técnica e na experiência prática em projetos de layouts desenvolvidos em diversas empresas. O objetivo principal desse trabalho foi desenvolver um modelo de fácil utilização que auxilie as pessoas envolvidas no projeto do arranjo físico. Esse modelo concebido utiliza ferramentas e conceitos da Produção Enxuta para analisar e projetar o novo layout, e como tal, não considera o layout como uma variável independente no sistema produtivo. Fatores como gestão visual, qualidade, fluxo contínuo, complexidade de programação da produção, entre outros, foram levados em consideração na construção do modelo. Este também incorpora uma metodologia de implantação do arranjo físico projetado em situações brown field, ou seja, com a fábrica em funcionamento. Esse ponto é de extrema importância pois alterações do layout podem incorrer em interrupções no fluxo produtivo e, conseqüentemente, em falhas na entrega dos produtos aos clientes. Por último, esse trabalho apresenta a metodologia 3P Kaizen, uma metodologia de projeto de layout industrial desenvolvida pela Toyota e utilizada em situações de projeto de novas fábricas ou de novas linhas de produção. / This work aims to show a model to analyze and design an industrial layout for companies that are implementing or have implemented lean manufacturing concepts. The model developed has a focus in discrete manufacturing companies in environments of high variety of products. The development of the model was based on the experience of layouts projects developed in many companies. The main aim of this work is to create an easy model of application that help people that are involved in the design of the facilities resources. This model utilizes tools and concepts of lean manufacturing to analyze and design a new layout, without considering the layout as an independent variable of production system. Aspects like visual management, quality, continuous flow, etc., were considered in the construction of the model. The layout design model presents also a methodology to implement a new layout projected in brown field situations, where the factory activities do not need to stop its activities. This point is very important because changing in the position of facilities resources can cause interruption in the flow of products. At last, this work shows the 3P Kaizen, a Japanese methodology, developed by Toyota, to design a layout of a new factory or a new production line.

Introduction: To improvement the target company’s manufacturing process by applyinglean principles, including using and analyzing the internal value stream mapping. Asmore and more companies have paid attention to implement lean thinking in theirmanufacturing process, the value stream mapping played an important role for manycompanies to make a transition from their traditional production systems to lean systems.The content and resources of this master thesis come from an American furniturecompany named KAMA which mainly produces office furniture with different components.Although there are various types of products, the authors merely focus on the officechair products. This research is an attempt to understand and analyze the problemsin the production flow on the example of KAMA’s office chair products that includesPH product family as the target research part.Purpose: The purpose of this research study is to investigate, analyze and find out solutionsfor waste-related problems in the office chair manufacturing flow of KAMA.Method: A single case study will be applied in this study paper. Data should be collectedfrom telephone interviews with company’s managements, the studying ofKAMA’s internal documentation and the secondary data from lean project report collectedby Consultant EIMI. In order to improve the production process, the valuestream mapping method will be applied to build the current value state map of CompanyKAMA and identify the potential wastes during the manufacturing process, andthen analyze and give the solutions for future improvement. Additional, other methodsincluding the order penetration point analysis, make-to-stock theory, and the CONWIPanalysis have been subsequently applied in designing a draft of the future state map.Conclusion: From the constructed current value stream mapping of KAMA officechair manufacturing process, it can be found that the most essential wastes are overproduction,waiting, unnecessary inventory and unnecessary movement. In addition, theimproper workstation arrangement and unnecessary waiting time have been identified asthe critical wasting reasons. Thus, any solutions to reduce or eliminate the identifiedwastes have been considered and would be given in the future state. In order to improvethe efficiency and reduce the unnecessary movements, adopting the appropriate cellularlayout in the mechanical workshop is quite beneficial. The mentioned methods to reducewastes have been summarized in the draft of the future state map of the company.The main benefits of the proposed future state value stream mapping are faster and accurateorder fulfillment process, reduction of unnecessary movements in workshop, lowinventory, high productivity and reduced costs in the flow of KAMA’s manufacturingprocess.

Nowadays business atmosphere is to constantly come up with new improvements, in order to become more competitive, or simply stay competitive.Lean manufacturing rose up few decades ago and is now famous for its radical improvements but also for its difficulty to implement. The aim of this study is to get a better understanding of how can Lean bring such important changes, but also what must be done in order to implement it.In order to solve the problem of this report, it was decided to conduct a quantitative research relying on a case study. The company chosen wants to implement Lean but does not really know how to achieve it, so it is a very good opportunity for this project to collaborate with it and see what can be done to implement Lean manufacturing.The results of this thesis demonstrate the need of implementing a philosophy, a way of thinking, rather than different production tools. People must also be prepared for long implementation, which can take between 5 to 10 years. One of the key factors for this implementation is the involvement and empowerment of workers, who will massively contribute to the change process by removing different kind of waste which slow down the processes.

<p>Introduction: To improvement the target company’s manufacturing process by applyinglean principles, including using and analyzing the internal value stream mapping. Asmore and more companies have paid attention to implement lean thinking in theirmanufacturing process, the value stream mapping played an important role for manycompanies to make a transition from their traditional production systems to lean systems.The content and resources of this master thesis come from an American furniturecompany named KAMA which mainly produces office furniture with different components.Although there are various types of products, the authors merely focus on the officechair products. This research is an attempt to understand and analyze the problemsin the production flow on the example of KAMA’s office chair products that includesPH product family as the target research part.Purpose: The purpose of this research study is to investigate, analyze and find out solutionsfor waste-related problems in the office chair manufacturing flow of KAMA.Method: A single case study will be applied in this study paper. Data should be collectedfrom telephone interviews with company’s managements, the studying ofKAMA’s internal documentation and the secondary data from lean project report collectedby Consultant EIMI. In order to improve the production process, the valuestream mapping method will be applied to build the current value state map of CompanyKAMA and identify the potential wastes during the manufacturing process, andthen analyze and give the solutions for future improvement. Additional, other methodsincluding the order penetration point analysis, make-to-stock theory, and the CONWIPanalysis have been subsequently applied in designing a draft of the future state map.Conclusion: From the constructed current value stream mapping of KAMA officechair manufacturing process, it can be found that the most essential wastes are overproduction,waiting, unnecessary inventory and unnecessary movement. In addition, theimproper workstation arrangement and unnecessary waiting time have been identified asthe critical wasting reasons. Thus, any solutions to reduce or eliminate the identifiedwastes have been considered and would be given in the future state. In order to improvethe efficiency and reduce the unnecessary movements, adopting the appropriate cellularlayout in the mechanical workshop is quite beneficial. The mentioned methods to reducewastes have been summarized in the draft of the future state map of the company.The main benefits of the proposed future state value stream mapping are faster and accurateorder fulfillment process, reduction of unnecessary movements in workshop, lowinventory, high productivity and reduced costs in the flow of KAMA’s manufacturingprocess.</p>

This study deals with a very common problem encountered in many automotive industries. Automotive companies try to level the production of different models over time based on the demands for these models in the market. In order to achieve this, they introduce a leveled stream of cars in the beginning of the production line. But because of many reasons this leveled stream gets disturbed in its course. In order to re-level the stream, buffers are used between the shops. One such buffer is called as selectivity bank and it sits between paint shop and assembly shop. This buffer receives a disturbed sequence from the paint shop. The thesis tries to develop different algorithms that can be used to discharge cars from this buffer in order to achieve better leveling in the presence of rework and assembly constraints. These algorithms continuously try to steer the system from an undesirable state to a more desirable state by keeping track of current conditions in the plant. A simulation model is developed, which gives a platform for comparing relative performance of these logics under different conditions. The simulation tool is also helpful in designing optimum size of this buffer that will result in desired leveling performance.

This thesis deals with development of lean and green production systems from an action research point of view. The studies focus on Swedish-based automotive and vehicle industries and their aims to integrate sustainable thinking and environmental care into their operations management. Starting from operations management in manufacturing and corporate sustainable development, the research is built on how to integrate these two views into one production system. The systematic structure of a multiple-target improvement process with methodologies and tools designed to achieve the sustainability vision has been studied. Since lean as well as green production is based on the entire value chain, the research has gone beyond legal company limits and included the collaborative efforts between suppliers and customers in the value chain. The thesis includes six papers and describes approaches on how to implement integration, how to structure and integrate improvement management systems, how to set up an integrated monitoring and control system for the business and how to organise and redesign green lean tools and methodologies to support collaboration towards common targets. The results can be used for exploration and hypothesis formulation for further studies and development of integrated production systems and collaboration systems. The thesis helps answering how to integrate and implement company-specific green lean production systems.

Thesis (M.S.)--State University of New York at Binghamton, Thomas J. Watson School of Engineering and Applied Science, Department of Systems Science and Industrial Engineering, 2009. / Includes bibliographical references.

Proponer alternativas de solución y nuevas metodologías operativas a fin de poder tener una planta de producción de línea que permita estar acorde con las tendencias del mercado y que a su vez asegure que la rentabilidad de la empresa aumente evitando roturas de stock que en consecuencia puede traer tener un mercado insatisfecho. Como objetivos específicos se tiene el determinar las áreas de oportunidad de mejora para reducir tiempos en la producción de tubos LAC. También el proponer una herramienta de mejora para incrementar la capacidad de producción de la línea de tubos LAC y el complemento para el desarrollo de la línea seria ejecutar mejoras en las áreas en las que existan ineficiencias para la producción de los tubos. / Tesis