Durante los últimos años, la industria metalmecánica ha demostrado ser un eslabón muy importante en la economía del Perú. Sin embargo, presenta desafíos como la baja productividad por incumplimiento de pedidos. En ese sentido, se estudió una PYME del sector que actualmente atraviesa esta problemática, el cual le genera pérdidas por penalidades. A partir de ello, se propuso un modelo de gestión de producción con la finalidad de optimizar métodos, organizar estaciones de trabajo, y mejorar la gestión de compras y de la producción, a través de la reducción o eliminación de desperdicios en empresas del sector metalmecánico. Se utilizó el Mapa de Flujo de Valor como herramienta de diagnóstico, junto con otras herramientas Lean, como Kanban, SMED, Poka-Yoke, Reporte A3 y 5S. De este modo, con la implementación del modelo, se espera un incremento en el cumplimiento de pedidos y la productividad, así como la reducción de tiempos de ciclo y de SETUP. La validación de la efectividad de este modelo se realizó mediante una simulación con el software Arena, la cual dio como resultado un incremento del cumplimiento de pedidos de 66.40% a 87.85%, y un incremento de la productividad de 27 tapas/H-H a 32 tapas/H-H. Asimismo, los tiempos de ciclo y de SETUP promedio se redujeron de 2.24 min/tapa a 1.86 min/tapa y de 28.32 min a 19.52 min respectivamente. Finalmente, se espera que este modelo, que vincula las herramientas Lean mencionadas, pueda ser replicado en otras empresas del sector metalmecánico o manufacturero que presenten desafíos similares. / In recent years, the metalworking industry has proven to be a very important link in the Peruvian economy. However, it presents challenges such as low productivity due to non-fulfillment of orders. In this sense, an SME in this sector that is currently experiencing this type of problem was studied, which generates losses due to penalties. Based on this, a production management model was proposed in order to optimize methods, organize work stations, and improve production and purchase management, through the reduction or elimination of waste in companies in the metalworking sector. The Value Stream Map (VSM) was used as a diagnostic tool, along with other Lean solution tools such as Kanban, SMED, Poka-Yoke, A3 Report and 5S. Thus, with the implementation of this model, an increase in order fulfillment and productivity is expected, as well as a reduction in cycle times and SETUP times. The validation of the effectiveness of this model was carried out through a simulation in the Arena software, which resulted in an increase in order fulfillment from 66.40% to 87.85% and an increase in productivity from 27 covers/HH to 32 covers/HH. In the same way, a reduction of the cycle time from 2.24 min/cover to 1.86 min/cover and the mean SETUP time from 28.32 min to 19.52 min was achieved. Finally, it is expected that this model, which links the mentioned Lean tools, can be replicated in other companies in the metalworking or manufacturing sector that present similar challenges. / Trabajo de investigación

One way to increase capacity is to optimise production. This research focuses on optimising material handling using Lean principles, factory layout analysis and supply & operation planning. The purpose is to see how the strategies found in these theories effect the change. An organisations readiness to change management shows how fast it can grow in a competitive world. The methodology used to collect data is by observations, interviews, literature review and secondary data. The research design is a case study, as it allows to collect multiple forms of data and mainly because it is done within a particular factory. The data analysis is done by forming themes, i.e., thematic analysis. Empirics were gathered from the company in focus about how their production runs. The empirics focused on the themes found by analysing data. The result gives strategies that can be followed for optimised material handling and the behaviour of employees and managers when change is suggested. The conclusion is that, although the changes were perceived in a positive way, with willingness to change, the subjects did not want to dig deeper into how they could benefit from it.

Global supply chains are facing significant challenges due to the changes in supply and demand. This will increase the need for flexible and sustainable management. Lean production is a widely adopted methodology that companies use to enhance efficiency, reduce costs, and shorten lead times by optimizing internal logistics systems. Mapping and visualization tools are essential for understanding and improving transportation processes within companies while minimizing waste.The objective of this study is to provide companies with clearer insights into theirinternal transport flows through lean production and facility planning. By mappingtheir structures, companies can enhance their decision-making processes. This studyaims to achieve an understanding of the need for internal transport flow mappingthrough various methods and analyses. It also seeks to increase knowledge ofdifferent tools within lean production and facility planning to visualize the currentstate of internal transportation between buildings.The study was conducted through interviews, observations, and GPS measurements to map the transport processes at Xylem. Data were analyzed both qualitatively and quantitatively to ensure high scientific quality. The results and current state analysiswere based on these methods, leading to reliable conclusions about Xylem's current state.By using various lean tools and facility planning techniques, it is possible to create a mapping that provides companies with insights into their current situation. Several improvement suggestions for the current structure and work methods can potentially create faster flows with fewer misunderstandings in the work process. The study concludes that flow mapping functions as a tool to create a simplified simulation model. By interviewing and observing drivers and using diagrams to show utilization and time distribution, it is possible to analyze and examine internal transport planning and identify unnecessary waste.

Bakgrund & Problemdiskussion: Lean består av en mängd olika verktyg som är skapade för olika ändamål, i syfte att skapa sig konkurrensfördelar gentemot andra företag. Användandet av metoden kan innebära att det blir bättre kommunikation, större tillit eller förbättringar i driftsekonomin. På senare år har det även kommit ett förändrat krav på företagen gällande miljön, vilket gjort att de inte endast kan fokusera på hur de kan förbättra de operativa processerna. Företagen försöker därför kombinera de traditionella prestationsmålen (ex: kvalitet & effektivitet) med miljömål. Här har det visat sig att Lean:s tankesätt även kan användas för att förbättra miljöprestationerna och skaffa sig konkurrensfördelar genom det. Men det är långt ifrån alla företag som implementerat metoden som lyckats att få konkurrensfördelar. Vilket beror på att företagen har bristande kunskaper över vilken påverkan de olika lean-verktygen har. Syfte: Syftet med denna studien är att identifiera vilka lean-verktyg svenska tillverkande företag arbetar med samt hur företagen arbetar med dessa. Vidare avser studien att öka förståelse över vilken uppfattad påverkan företags arbete med lean-verktygen har på driftsekonomin och miljöprestationerna. Metod: Tillvägagångssättet utgår ifrån en komparativ flerfallsstudie med kvalitativ karaktär. Materialet är inhämtat från tre tillverkande företag. Intervjuerna är genomförda genom strukturerade frågor via mail, samt semi-strukturerade frågor via telefon. Den inhämtade datan är sedan analyserad för att finna likheter och skillnader mellan fallföretagen, men även gentemot tidigare forskningen. Slutsats: Utifrån denna studien visar det sig att företagen anpassar sitt användande av de olika lean-verktygen till sin verksamhet. Där användandet av lean-verktygen upplevs påverka att det blir ett större kundfokus i företagen. Arbetet med lean-verktygen upplevs även bidra till att det blivit bättre kvalitet på företagen produkter och processer, samt att flexibiliteten och pålitligheten kunnat förbättras. I denna studien visar det sig även att företag börjar tänka mer på hur deras processer och produkter påverkar miljön. Där arbetandet med lean-verktygen visat sig att företagens miljöprestationer kan förbättras. I denna studien visar det sig att användandet av lean-verktygen bidragit till att materialanvändningen kunnat reducerats. / Background and problem discussion: Lean consists of a variety of tools that have been created for different purposes, in order to create competitive advantages over other companies. The use of the method can mean that they become better communication, greater confidence or improvements in the operating economy. In recent years there has also been a changed demand for companies regarding the environment, which means that they can not focus only on how they can improve the unproductive processes. The companies are therefore trying to combine the traditional performance goals (eg: quality & efficiency) with environmental goals. Here it has been found that Lean's way of thinking can also be used to improve environmental performance and gain competitive advantages through it. But it is far from all companies that have implemented the method that managed to gain competitive advantage. This is because companies have a lack of knowledge about the impact of the various lean tools. Purpose: The purpose of this study is to identify which Lean tools Swedish manufacturing companies work with and how the companies work with them. Furthermore, the study aims to increase understanding of the perceived impact that companies' work with lean tools have on the operating economy and environmental performance. Method: The approach is based on a comparative multi-case study with qualitative character. Where the material is obtained from three manufacturing companies. The interviews were conducted through structured questions via mail, as well as semi-structured questions via telephone interviews. The collected data is then analyzed to find similarities and differences between the fall companies, but also against previous research. Conclusion: Based on this study, it appears that companies are adapting their use of the various lean tools to their business. Where the use of the lean tools is perceived to affect their becoming a greater customer focus in the companies. The work with the lean tools is also perceived to contribute to improving the quality of the companies products and processes, and that flexibility and reliability could be improved. In this study it also turns out that companies are starting to think more about how their processes and products affect the environment. Where working with the lean tools has shown that companies' environmental performance can be improved. In this study, it appears that the use of the lean tools has contributed to the reduction in material use.

Syftet med detta examensarbete har varit att ta fram vilka leanprinciper och leanverktyg som passar en processindustri med målet att minska ledtiden. För att kunna genomföra studien har en jämförelse mellan teori och verklighet gjorts där hjälp tagits av Lesjöfors industrifjädrar AB. Utmärkande aspekter för företagets produktion är långa led- och omställningstider, produktion i batcher med stora partistorkekar samt tryckande tillverkning. Litteraturstudien omfattar fem principer och fem verktyg. För att identifiera nuläget har en värdeflödeskartläggning genomförts samt intervjuer med anställda på företaget. När teori kopplas med empiri har lämpliga principer och verktyg utifrån de studerade 10 valts ut. De principer som har identifierats som lämpliga för en processindustri är standardiserat arbetssätt, ständiga förbättringar, utjämnad produktion. De verkyg som utefter principerna identifierats som lämpliga är SMED, 5S samt värdeflödeskartläggning. Dessa har sedan används i en sammanfattning i form av ett TPS-hus, unikt för produktionen på Lesjöfors industrifjädrar AB. / The aim of this bachelor thesis has been to identify which lean principles and lean tools that would suit a process industry with the goal of reducing lead times. In order to complete the study, a comparison between theory and reality has been made where assistance has been provided by Lesjöfors industrifjädrar AB. Key aspects of the company's production include long lead times and set up times, production in batches with large lots and push production. The literature study comprises five principles and five tools. To identify the current situation, a value stream mapping has been conducted and interviews with employees at the company. When theory is linked with empirical studies, suitable principles and tools based on the selected 10 have been chosen. These have then been used in a summary in the form of a TPS-house, unique to the production at Lesjöfors industrifjädrar AB.

The purpose of this research is to implement and analyze the true lean transformation in a manufacturing start-up organization. Often, lean transformations are observed in developed manufacturing organizations having sophisticated production lines and numerous employees, where lean tools are utilized to reduce waste while increasing profit. However, this type of transformation is narrowly focused on quantifiable process results and falls short of the ultimate goal, establishing a true lean culture within the organization. As a result, it is recommended that true lean principles, philosophies, culture, operations environment and tools be applied at the very beginning stages of an organization, or during the start-up phase to embed true lean thinking and application in the entirety of the organization. In this analysis, a case study is performed on a team embarking on a start-up manufacturing enterprise. The team is trained on true lean and all the four aspects of true lean are applied for successfully implementing true lean in the start-up. In addition, a true lean implementation approach was generated and applied using PDCA (plan, do, check and act) model. The results of this case study are presented in this work.

Investigación que desarrolla un modelo de estandarización y mejora de los procesos productivos en una empresa de fabricación de calcetines. El caso de estudio presentado consta con todas las etapas de investigación requeridas como son la revisión de la literatura existente a través de un marco teórico, posterior identificación de diagnóstico de situación actual, generación y validación de propuesta de solución afianzando que los resultados obtenidos son respaldados en cada uno de los escenarios propuestos. La presente propuesta de valor propone motivar la investigación en industrias de pequeña escala en el Perú y generar un abanico de soluciones a los diferentes problemas de la industria que cuentan con menores recursos. La metodología está diseñada por el autor que consiste en la propuesta de un modelo de estandarización de los procesos de producción en una empresa de fabricación de calcetines, basándose en otros casos de éxito en la aplicabilidad de las herramientas de gestión propuestas. El logro de objetivos como el tiempo de procesamiento fue reducido, así como una reducción de productos defectuosos y del tiempo improductivo logrando un mayor flujo de los procesos productos y eliminando el cuello de botella identificado. La investigación propone la generación del desarrollo de nuevas investigaciones para la estandarización de procesos en la industria de calcetines de pequeña y mediana escala. El documento arroja muchos valores para que los profesionales comprendan los impactos e importancia de la estandarización en las industrias de pequeña y mediana escala del Perú. / Research that develops a model for standardization and improvement of production processes in a sock manufacturing company. The case study presented consists of all the required research stages, such as the review of the existing literature through a theoretical framework, subsequent identification of the current situation diagnosis, generation and validation of the solution proposal, ensuring that the results obtained are supported. in each of the proposed scenarios. This value proposition proposes to motivate research in small-scale industries in Peru and to generate a range of solutions to the different problems of the industry that have fewer resources. The methodology is designed by the author, that consists of the proposal of a model for the standardization of production processes in a sock manufacturing company, a function in successful cases in the applicability of the proposed management tools. The achievement of objectives such as processing time was reduced, as well as a reduction in defective products and downtime, achieving a greater flow of product processes and eliminating the identified bottleneck. The research proposes the generation of the development of new research for the standardization of processes in the small and medium-scale socks industry. The document shows many values ​​for professionals to understand the impacts and importance of standardization in small and medium-scale industries in Peru. / Trabajo de Suficiencia Profesional

Las herramientas lean se utilizan ampliamente en las industrias para reconocer y eliminar actividades o procesos sin valor agregado. Con el objetivo de un uso eficaz de los recursos y reducción de los tiempos de entrega, desperdicio y aumento de la satisfacción del cliente. Sin embargo, varias pymes no saben cómo identificar su propuesta de valor, como el tiempo de entrega, por lo que no aplican metodologías correctas para mejorar sus procesos que apoyan la propuesta de valor. Por ello, en esta investigación se propone la implementación de herramientas Lean de forma secuencial en base a un nuevo flujo de producción sobre recursos multifuncionales para optimizar procesos que reducirán el tiempo de entrega y atenderán la demanda. Las herramientas Lean utilizadas fueron: 5'S junto con Método de Trabajo y Gestión Visual junto con Distribución de Planta, Balance de Línea y Estandarización de Procesos. Este modelo de propuesta se aplicó en una pyme que produce cuadros eléctricos y como resultado se logró reducir el tiempo de fabricación en un 15%, satisfaciendo la demanda en un 90%, así mismo se redujeron los costos posventa en un 90%. / Lean tools are widely used in industries to recognize and eliminate activities or processes without added value. With the objective for an effective use of resources and reduction of delivery time, waste and increase customer satisfaction. However, several SMEs do not know how to identify their value proposal, such as the delivery time, so they don’t apply correct methodologies to improve their processes that support thevalue proposition. For this reason, in this research it is proposed that the implementation of Lean tools sequentially based on a new production flow on multifunctional resources to optimize processes that will reduce delivery time and meet the demand. The Lean tools used were: 5'S together with Work Method and Visual Management along with Plant Distribution, Line Balance and Process Standardization. This proposal model was applied in a SME that produces electrical panels and as a result it was possible to reduce the manufacturing time by 15%, satisfying the demand by 90%, likewise, the post-sale costs were reduced by 90%. / Trabajo de Suficiencia Profesional

Titel: Att växa med Lean Bakgrund:  Lean är en metod för verksamhetsstyrning som syftar till att minska slöseri i form av tid och och kostnader samt förbättra effektiviteten i organisationen. Från dess att Lean introducerades av Toyota på 1950-talet har Lean diskuterats utifrån olika perspektiv. Perspektiven är Lean utifrån ständiga förbättringar samt Leans för- och nackdelar. Utifrån det förstnämnda diskuteras Lean ofta utifrån produktutveckling och förändringsprocesser. Vid den andra vanligt förekommande diskussionen om Lean pratas det om  metodens för- och nackdelar. Det  debatterar ofta om Lean i positiv bemärkelse och de främsta fördelarna som lyfts fram är att Lean är en metod som främjar effektiviteten i ett företag. Å andra sidan, beskrivs Lean vara ett komplext koncept där beskrivningen av begreppet hos flera anses vara diffust. Syfte: Syftet med denna uppsats är att skapa en ökad förståelse av hur utvecklingen av användandet av Lean ser ut efter flera år i organisationen. En förståelse av de kritiska faktorer som kan uppstå kommer att skapas och man får en insyn av vilka utmaningar som eventuellt  uppstår när lean funnits i en organisation under en längre period. Metod: Studien är en fallstudie som undersöker hur utvecklingen av Lean-användander sett ut under en längre period och vilka kritiska faktorer som uppstår under denna tid i ett företaget. Studien utgår från en kvalitativ forskningsstrategi med en induktiv forskningsprocess, där det empiriska materialet samlats in genom sex semistrukturerade intervjuer. Slutsats: Utvecklingen av Lean kan beskrivas som en tidslinje enligt faserna Bristen, Systemet, Födseln, Ungdomen, Livslångt projekt, Tillväxt, Människan och Krisen, där Krisen kan inträffa när som under tidslinjens gång. Kritiska faktorer för att bibehålla Lean i en organisation under en längre period omfattas av delaktiga ledare som arbetar nära medarbetarna, utbildning av medarbetarna om syftet med Lean och insikten i att Lean är ett livslångt projekt där anpassningen aldrig tar slut. Vidare är en kritisk faktor att inte bli alltför byråkratisk, utan fortsätta låta medarbetarna ta beslut. Att stirra sig blind på enskilda Lean-verktyg och inte se Lean utifrån ett helhetsperspektiv är också en kritisk faktor. Den sista kritiska faktorn är att skapa delaktighet för medarbetarna. / Title: To grow with Lean Background: Lean is a method of operational management aimed at reducing waste in the form of time and costs, as well as improving efficiency within an organization. Since its introduction by Toyota in the 1950s, Lean has been discussed from various perspectives, namely continuous improvement and the advantages and disadvantages of Lean. The former perspective often focuses on Lean in the context of product development and change processes. The latter, more common discussion about Lean, revolves around the method's pros and cons. There is often a debate regarding Lean in a positive light, highlighting its main advantages, such as promoting efficiency within a company. On the other hand, Lean is described as a complex concept, with the description of the term considered ambiguous by several sources. Purpose: The purpose of this essay is to enhance the understanding of how the development of Lean utilization evolves after several years within the organization. By gaining insight into the critical factors that may arise, one can acquire an understanding of the challenges that may potentially emerge when Lean has been present in an organization for an extended period. Method: The study is a case study that examines the development of Lean utilization over an extended period and the critical factors that arise during this time in a company. The study adopts a qualitative research strategy with an inductive research process, where the empirical data has been collected through six semi-structured interviews. Conclusion: The development of Lean can be described as a timeline consisting of the phases of Gap, System, Birth, Youth, Lifelong Project, Growth, Human, and Crisis, where the Crisis phase can occur at any point along the timeline. Critical factors for sustaining Lean in an organization over an extended period include engaged leaders  working closely with employees, educating employees about the purpose of Lean, and understanding that Lean is an ongoing project where adaptation never ceases. Additionally, a critical factor is to avoid excessive bureaucracy and continue empowering employees to make decisions. Focusing solely on individual Lean tools and failing to see Lean from a holistic perspective is also a critical factor. Lastly, creating employee involvement and participation is crucial.