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The slow rate of corporate improvement is not due to lack of knowledge of six sigma or lean. Rather, the fault lies in making the transition from theory to implementation. Managers need a step-by-step, unambiguous roadmap of improvement that leads to predictable results. This roadmap provides the self-confidence, punch, and power necessary for action and is the principal subject of this research. Unique to this research is the way the integration of lean and six sigma is achieved; by way of an integration matrix formed by lean implementation protocols and six sigma project phases. This integration matrix is made more prescriptive by an integrated leanness assessment tool, which will guide the user given their existing level of implementation and integration. Further guidance in each of the cells formed by the integration matrix is provided by way of phase methodologies and statistical/non-statistical tools. The output of this research is a software tool that could be used in facilities at any stage of lean implementation, including facilities with no existing lean implementation. The developed software tool has the capability to communicate among current and former project teams within any group, division, or facility in the organization. The developed software tool has also the capability to do data analysis (Example: Design of Experiments, Value Stream Mapping, Multi-Vari Analysis etc.). By way of the integration matrix, leanness assessment and the data analysis capability, the developed software tool will give managers a powerful tool that will help in their quest to achieve lean six sigma. / Master of Science

As empresas estão utilizando diversos processos de melhoria para adequarem seus negócios às necessidades dos clientes, à maior concorrência, a uma necessidade de flexibilização e de redução dos custos de seus processos de manufatura. O seis sigma e a produção enxuta são dois processos utilizados por empresas no Brasile no mundo. Atualmente a integração destes processos é um desafio para essas empresas, que buscam uma maneira mais eficiente de reduzir seus desperdícios e se adaptarem às necessidades de seus mercados consumidores. Surge, assim, o Lean Sigma aplicado nas empresas de diversas formas. O objetivo deste trabalho é estruturar, por meio de dois estudos de caso, como as empresas estão utilizando o seis Sigma e a Produção Enxuta em seus processos de melhoria. Verificou-se que existem diferentes formas de utilizar os processos em paralelo: na primeira empresa o processo iniciou em conjunto e depois foi separado em dois processos paralelos de melhoria. A segunda empresa foi ao contrário, começando de forma paralela, desagregada, e posteriormente se unindo em um único processo de melhoria, denominado Lean Sigma. O trabalho apresenta uma sistematização do processo de melhoria de duas empresas, dividido em Visão Geral e Objetivos, Estrutura Organizacional e Métodos de Melhoria. Foram verificadas as formas gerais de utilização dos processos de melhoria e que uma abordagem integrada, que contemple as peculiaridades de cada processo, se demonstra como uma melhor opção para um processo de melhoria que utiliza a Produção Enxuta e o Seis Sigma paralelamente. A pesquisa traz, também, como resultado, uma proposta de sistematização do Lean Sigma, considerando o conhecimento adquirido nos estudos de caso e na literatura consultada. / Enterprises are using several improvement processes to adequate their business to the clients needs, to the higher competition, to a need of been more flexible and to reduce the costs of their manufacturing costs. The Six Sigma and the Lean Production are two processes using by enterprises in Brazil and the world wide. Nowadays the integration of those two processes is a challenge to enterprises that search a more efficient way to reduce their wastes and get adapted to the needs of their markets. With this objective the Lean Sigma appears, been applied in the enterprises differently. The dissertation objective is to understand, trough two case studies, how enterprises are connecting Six Sigma and Lean Production in their improvement processes. It was verified that are several ways to run the processes in parallel: in the first enterprise, the two processes was integrated and them shared into two process in parallel. The second enterprise showed the opposite approach, beginning disintegrated, in parallel, and them running together in one improvement processes, called Lean Sigma. The dissertation presents the systematization of the improvement processes of these two enterprises, organized as follow: Global vision and Objectives, Organizational Structure and Improvement Method. Was verified the general approach used in the improvement process and that the integrated approach, that consider the peculiarities of each process, showns as a best option to run Lean Production and Six Sigma in parallel. The research presents, as a result too, a systematization proposal for Lean Sigma, considering the case studies and the consulted literature.

As empresas estão utilizando diversos processos de melhoria para adequarem seus negócios às necessidades dos clientes, à maior concorrência, a uma necessidade de flexibilização e de redução dos custos de seus processos de manufatura. O seis sigma e a produção enxuta são dois processos utilizados por empresas no Brasile no mundo. Atualmente a integração destes processos é um desafio para essas empresas, que buscam uma maneira mais eficiente de reduzir seus desperdícios e se adaptarem às necessidades de seus mercados consumidores. Surge, assim, o Lean Sigma aplicado nas empresas de diversas formas. O objetivo deste trabalho é estruturar, por meio de dois estudos de caso, como as empresas estão utilizando o seis Sigma e a Produção Enxuta em seus processos de melhoria. Verificou-se que existem diferentes formas de utilizar os processos em paralelo: na primeira empresa o processo iniciou em conjunto e depois foi separado em dois processos paralelos de melhoria. A segunda empresa foi ao contrário, começando de forma paralela, desagregada, e posteriormente se unindo em um único processo de melhoria, denominado Lean Sigma. O trabalho apresenta uma sistematização do processo de melhoria de duas empresas, dividido em Visão Geral e Objetivos, Estrutura Organizacional e Métodos de Melhoria. Foram verificadas as formas gerais de utilização dos processos de melhoria e que uma abordagem integrada, que contemple as peculiaridades de cada processo, se demonstra como uma melhor opção para um processo de melhoria que utiliza a Produção Enxuta e o Seis Sigma paralelamente. A pesquisa traz, também, como resultado, uma proposta de sistematização do Lean Sigma, considerando o conhecimento adquirido nos estudos de caso e na literatura consultada. / Enterprises are using several improvement processes to adequate their business to the clients needs, to the higher competition, to a need of been more flexible and to reduce the costs of their manufacturing costs. The Six Sigma and the Lean Production are two processes using by enterprises in Brazil and the world wide. Nowadays the integration of those two processes is a challenge to enterprises that search a more efficient way to reduce their wastes and get adapted to the needs of their markets. With this objective the Lean Sigma appears, been applied in the enterprises differently. The dissertation objective is to understand, trough two case studies, how enterprises are connecting Six Sigma and Lean Production in their improvement processes. It was verified that are several ways to run the processes in parallel: in the first enterprise, the two processes was integrated and them shared into two process in parallel. The second enterprise showed the opposite approach, beginning disintegrated, in parallel, and them running together in one improvement processes, called Lean Sigma. The dissertation presents the systematization of the improvement processes of these two enterprises, organized as follow: Global vision and Objectives, Organizational Structure and Improvement Method. Was verified the general approach used in the improvement process and that the integrated approach, that consider the peculiarities of each process, showns as a best option to run Lean Production and Six Sigma in parallel. The research presents, as a result too, a systematization proposal for Lean Sigma, considering the case studies and the consulted literature.

A l’image des grands groupes, les PME souhaitent, elles aussi, profiter des méthodes modernes de management pour améliorer leurs processus, leurs performances et leur compétitivité. L’intérêt du secteur des PME se porte sur les éléments du concept Lean Six Sigma qui leur semblent appropriés pour réaliser ces objectifs. Après avoir constaté une lacune dans les recherches sur ce sujet et une lacune méthodologique concernant l’implémentation du LSS dans les PME, nous proposons une méthodologie de conception, d’application et de contrôle du LSS pour ces PME, que nous avons appelée LSS Plutus. Elle est dédiée aux PME de la production et elle prend en compte leur spécificité. Dans ce but, nous avons restreint la boîte à outils traditionnelle du LSS utilisée dans les grands groupes. Nous avons également créé deux variantes pour mettre en œuvre notre méthodologie qui correspondent aux besoins, capacités et maturités différents des PME. Nous avons élaboré des indicateurs, des outils, ainsi qu’un guide d’application de la méthode LSS pour les PME de la production et sa version informatique en TIBCO. Nous avons décidé de renforcer l’efficience des améliorations, en déployant les actions de planification, de standardisation et de pérennisation des changements. Dans ce but, nous proposons de modifier les critères du Modèle d’Excellence E.F.Q.M. pour qu’elles puissent prendre en compte les conditions de fonctionnement de la méthode LSS dans les PME. La méthodologie proposée a été vérifiée dans deux PME de la production en Pologne et en France, ce qui a confirmé son utilité et son efficacité en termes d’amélioration des performances et de développement des organisations / As well as the large companies, also the small and medium-sized enterprises desire to take advantage of modern management methods to improve their process, their performances and competitiveness. The interest of the SMEs is focused on the elements of the Lean Six Sigma concept that seem to be appropriate to achieve these goals. As we have identified a gap in the research on this topic and a methodological gap about the LSS implementation in the small and medium companies, we propose a methodology that we called LSS Plutus to design, apply and control Lean Six Sigma in the SMEs. It is dedicated to the small and medium production enterprises and it takes into account their specificity. For this purpose, we have limited the traditional LSS toolbox used by the large companies. We have also created two variants to apply our methodology according to the different needs, capacities and maturities of the SMEs. We have developed indicators, tools, as well as a practical guide for applying the LSS for the production SMEs and its computerized version in TIBCO. To enhance the efficiency of the improvements, we have deployed the planning, standardization and sustainability of the changes. For this purpose, we propose to modify the criteria of the EFQM Excellence Model in order to adapt it to the operating conditions of the Lean Six Sigma method in the SMEs. The proposed methodology has been verified in two production SMEs in Poland and in France that confirmed its utility and effectiveness in terms of performance improvement and organizational development

Cada vez mais presentes no ambiente industrial, as metodologias de melhoria contínua estruturam e sistematizam a implantação e a aplicação de técnicas, ferramentas e práticas de melhoria dos processos, que permitem reduzir o lead time, aumentar a satisfação do cliente, diminuir a variabilidade dos processos e elevar a qualidade do produto. Neste contexto, o objetivo deste trabalho é, com o auxílio de um framework teórico, estudar o uso de Lean Manufacturing e Six Sigma em um caso real pertencente ao parque industrial nacional. Dessa forma, optou-se por realizar um estudo de caso em uma empresa do ramo automobilístico, visto a relação do setor com a melhoria contínua. A companhia já utilizava as técnicas e ferramentas há mais de uma década e, além de mostrar a sua abordagem com relação à melhoria contínua de forma geral, apresentou dois casos para comparação das soluções encontradas para seu próprio aperfeiçoamento. Foi observado que a empresa encontra-se em um estágio intermediário-avançado dentro do framework construído e foi ressaltado que o Kaizen é a principal forma de melhoria usada. / Increasingly present in industrial environment, the continuous improvement methodologies structured and systematized the implementation and employment of techniques, tools and practices of process improvement, which allow reducing lead time, enhancing customer satisfaction, decreasing process variability and raising product quality. In this context, supported by a framework, what this study aims at is to review the use of Lean Manufacturing and Six Sigma in a real case belonging to the national industrial park. Hence, a case study was chosen in a company from the automotive industry, insofar as its relationship with continuous improvement. The company had already been using the techniques and tools for over a decade and it was provided an overview of its approach and, in addition, two cases to have their solution compared. It was observed that the company stands in an upper intermediate stage according to the developed framework and it was also highlighted that Kaizen is the main improvement means used.

Cada vez mais presentes no ambiente industrial, as metodologias de melhoria contínua estruturam e sistematizam a implantação e a aplicação de técnicas, ferramentas e práticas de melhoria dos processos, que permitem reduzir o lead time, aumentar a satisfação do cliente, diminuir a variabilidade dos processos e elevar a qualidade do produto. Neste contexto, o objetivo deste trabalho é, com o auxílio de um framework teórico, estudar o uso de Lean Manufacturing e Six Sigma em um caso real pertencente ao parque industrial nacional. Dessa forma, optou-se por realizar um estudo de caso em uma empresa do ramo automobilístico, visto a relação do setor com a melhoria contínua. A companhia já utilizava as técnicas e ferramentas há mais de uma década e, além de mostrar a sua abordagem com relação à melhoria contínua de forma geral, apresentou dois casos para comparação das soluções encontradas para seu próprio aperfeiçoamento. Foi observado que a empresa encontra-se em um estágio intermediário-avançado dentro do framework construído e foi ressaltado que o Kaizen é a principal forma de melhoria usada. / Increasingly present in industrial environment, the continuous improvement methodologies structured and systematized the implementation and employment of techniques, tools and practices of process improvement, which allow reducing lead time, enhancing customer satisfaction, decreasing process variability and raising product quality. In this context, supported by a framework, what this study aims at is to review the use of Lean Manufacturing and Six Sigma in a real case belonging to the national industrial park. Hence, a case study was chosen in a company from the automotive industry, insofar as its relationship with continuous improvement. The company had already been using the techniques and tools for over a decade and it was provided an overview of its approach and, in addition, two cases to have their solution compared. It was observed that the company stands in an upper intermediate stage according to the developed framework and it was also highlighted that Kaizen is the main improvement means used.

Globalization has increased the complexity of the business world, as it adds new dimensions to companies’ operations, such as global suppliers and customers, and competition from global actors. To handle the complexity, companies are pressured to become more data-driven to be able to measure and align their operations, and create possibilities for efficiency and competitiveness [Skjott-Larsen etal., 2007; Long, 2018]. In order to enable the change towards becoming more data-driven, companies need to rethink the structure of their organization. Matrix structures have gained popularity, since it allows companies to focus on more than one dimension by creating functional teams focused on specific tasks [Sy et al., 2005]. However, it is not uncommon that the functional groups becomes functional silos, with an inward focus on the own groups’ performance, leading to decreased understanding of other groups and poor communication between groups. A lack of understanding of other groups can lead to a reactive, rather than proactive, way of handling problems [Motiwalla and Pearson, 2009]. The purpose of this project is to create a process that can be used to facilitate proactive work in adata-driven matrix organization struggling with a reactive way of handling problems. The process can be used as a way to decide between possible solutions in decision-making processes, while making sure that any affected department is involved at an early stage in the decision-making process. At Alfa Laval’s distribution center (DC) in Tumba, they are facing the challenges of functional silos and reactive work. The organization is data-driven, why a lot of decisions are based on data. However, the best decision according to the data is not always feasible, which has lead to decisions being made that affects other departments negatively. Based on data from and observations made at the DC, a processwas created. The process was iterated and improved through application to real-life problems and point of improvements identified at DC Tumba. While it is based on the operations at Alfa Laval, it canbe applied to any organization facing similar challenges. The final version of the process proved to deliver good solutions to problems by involving stakeholders early on in the process, making it possible for them to influence how the solutions should be adjusted in order to avoid the changes affecting their daily work negatively. The most important conclusion is that important stakeholder departments should be involved earlyin decision-making processes. That way, their valuable competence and knowledge can be utilized when identifying possible solution, and any negative effects of a solution on another departments can be discovered before implementation. In addition, by taking the time to thoroughly analyze the root cause and effects to a problem, the understanding of the chain can increase. / Globalisering har ökat komplexiteten av affärsvärlden, då ytterligare dimensioner måste tas hänsyn till i företags verksamheter, så som globala leverantörer och kunder, och ökad konkurrens från globala aktörer. För att hantera komplexiteten blir företag mer datadrivna, för att kunna mäta och samordna sin verksamhet och skapa möjligheter för effektivitet och konkurrenskraftighet [Skjott-Larsen et al.,2007; Long, 2018]. För att möljiggöra ett skifte mot att bli mer datadriven, måste företag se över sin organisationsstruktur. Matrisstrukturer har ökat i popularitet då de möjliggör att företag kan fokusera på fler än en dimensioner samtidigt genom att skapa funktionella grupper fokuserade på specifikauppgifter [Sy et al., 2005]. Dock är det inte ovanligt att funktionella grupper förvandlas till funktionella silos, med ett inåtriktat fokus på den egna gruppens prestationer, vilket leder till minskad förtåelse och bristfällig kommunikation grupper emellan. Bristande förståelse för andra grupper kan leda till ett klimat där problem hanteras reaktivt snarare än proaktivt [Motiwalla and Pearson, 2009]. Syftet med detta projekt är att skapa en process som kan användas för att underlätta proaktivt arbetet i en datadriven organisation där problem hanteras reaktivt. Processen kan användas som ett hjälpmedel för att välja den bästa av flera möjliga lösningar, samtidigt som påverkade avdelningar involveras i ett tidigt stadium av beslutsprocessen. På Alfa Lavals distributionscenter (DC) i Tumba, finns utmaningar med funktionella silos och reaktivt arbete. Organisationen är datadriven, och beslut fattas baserat på data. Dock är inte alltid beslut som baserats på data rimliga, vilket har lett till att beslut tas som påverkar andra avdelningar negativt. Baserat på data från och observationer på DCt, skapades en preliminär process. Processen itererades och förbättrades sedan genom att appliceras på verkliga problem och förbättringsområden som identifierades på DC Tumba. Även om processen togs fram och baserades på Alfa Lavals verksamhet, kan den appliceras på andra organisationer som står inför samma utmaningar. Den slutgiltiga versionen av processen visade sig generera bra lösningar till problemen genom att involvera intressenter tidigt i processen, vilket gav dem möjligheten att påverka hur den rekommenderade lösningen skulle justeras för att undvika att dereas dagliga arbete skulle påverkas negativt. Den viktigaste slutsatsen är att det är viktigt att involvera intressentavdelningar i ett tidigt skede i beslutsfattandeprocesser. På så sätt kan deras värdefulla kompetens och kunskaper nyttjas när potentiella lösningar till ett problem genereras, och negativa effekter från lösningen på andra avdelningar kan upptäckas innan implementering. Att dessutom noggrant analysera roten till problemet och dess effekter kan leda till att förståelsen för hela kedjan ökar.

[pt] Atualmente é cada vez mais importante que uma empresa ganhe destaque, garantindo maior competitividade no seu mercado. Independentemente da área de atividade, ações de melhoria dos serviços e ou produtos, que aprimorem (i) qualidade dos serviços, (ii) aumentem a competitividade e (iii) aumentem poder de penetração, são cada vez mais valorizadas. Nesse cenário, laboratórios de ensaio e calibração acreditados (LECA) buscam manter e aumentar a qualidade dos seus serviços, o que se reflete tanto na satisfação por parte dos clientes quanto na obtenção e manutenção de acreditação. Desta forma, a presente dissertação visa propor um modelo hibrido (Kaizen e Lean Six Sigma) de avaliação da melhoria contínua da qualidade para laboratórios de ensaio e calibração, contribuindo para o aperfeiçoamento dos processos e as análises realizadas em LECA, visando tanto a redução de custos e desperdícios quanto a garantia da qualidade pós acreditação. Para tanto, foi realizada uma pesquisa survey com profissionais que atuam em diferentes setores de LECA de forma a se obter um perfil dos desafios associados a qualidade dos mesmos. Os resultados obtidos permitiram calcular o nível de maturidade de cada requisito analisado, identificando o requisito Pessoal como o de maior prioridade (menor maturidade). Com base nos resultados foi proposto tanto um modelo de avaliação continua da qualidade a ser empregado em LECA quanto recomendações de gestão da qualidade. / [en] Currently, it is increasingly important for a company to stand out, ensuring greater competitiveness in its market. Regardless of the field of activity, actions aimed at improving services and/or products, which enhance (i) service quality, (ii) competitiveness, and (iii) market penetration, are increasingly valued. In this scenario, testing and calibration laboratories (TCL) seek to maintain and increase the quality of their services, which is reflected both in customer satisfaction and in obtaining and maintaining accreditation. Thus, this dissertation aims to propose a hybrid model (Kaizen and Lean Six Sigma) for evaluating continuous quality improvement for testing and calibration laboratories, contributing to the improvement of processes and analyses conducted in TCL, aiming at both cost and waste reduction and ensuring post-accreditation quality. To this end, a survey was conducted with professionals working in different TCL sectors in order to obtain a profile of the challenges associated with their quality. The results obtained allowed the calculation of the maturity level of each analyzed requirement, identifying the Personnel requirement as the highest priority (lowest maturity). Based on the results, both a continuous quality evaluation model to be employed in TCL and quality management recommendations were proposed.

This diploma thesis deals with problematic of enterprise process management. Several process management approaches are described in the first, theoretical part of the thesis, with focus on Lean Six Sigma concept as a main theory, which is used in analytical and suggestional part of this thesis. The analytical part consists of process mapping and analyzation with purpose of finding weak spots of this process. This part is followed by suggestional part, where are collected improvement suggestions. These suggestions are then evaluated and the best ones are analzyed to find potential ammount of savings.