This diploma thesis is focused on examining the activities of production planning and examining the efficiency of the selected machine in the selected company. The theoretical part summarizes the most important findings and methods of lean manufacturing and corrective measures to prevent or eliminate downtime. In the analytical part, the selected machine is examined in terms of the production process, then an analysis of the current state and assessment of the collected data is performed. Furthermore, an analysis of the decision-making process in production planning for a selected machine was performed and shortcomings in planning were assessed. The practical part contains suggestions for removing the identified bottlenecks.

No / Due to significant challenges and increase in competition within the global environment, manufacturing companies need to focus on Manufacturing Planning and Control (MPC) systems in order to gain a competitive edge. This research paper describes a contribution towards the design and implementation of a bespoke MRP II system for a SME company dealing in tool reclamation. The paper covers the investigation of currently available MRP II systems and also investigates the present MPC system of the concerned SME company. On the basis of these investigations, a new/bespoke design has been proposed and developed for an MRP II system that is tailor-made for the aforementioned company. The newly designed MRP II system has been developed (using MS Access and Visual Basic for Application i.e. VBA) as a database planning tool of MPC system and contains the critical modules Demand Management (DM), Rough Cut Capacity Planning (RCCP), Master Production Scheduling (MPS), Material Requirements Planning (MRP), and Capacity Requirements Planning (CRP). The bespoke MRP II system has been tested within the real manufacturing environment existing in the SME company with positive results. The key outcome of the research has shown that even small SME’s can design and implement their own MRPII system, which is particular and relevant to their own special manufacturing environment, using a minimal of time, software and financial resources.

Orientador: Antonio Batocchio / Dissertação (mestrado profissional) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-06T08:19:28Z (GMT). No. of bitstreams: 1 Barbeiro_FranciscoMiguel_M.pdf: 3666365 bytes, checksum: 90bcb4b2a8648ea08f9f8360c1b7ed50 (MD5) Previous issue date: 2005 / Resumo: O Planejamento de Vendas e Operações é um processo integrado de gerenciamento do negócio, que pode gerar vantagem competitiva através de uma visão e entendimento do cenário futuro e do envolvimento de um time multifuncional para definir e executar um conjunto de planos operacionais alinhados de modo a maximizar os resultados do negócio e melhor atender os clientes. Este trabalho tem como objetivo apresentar uma metodologia que suporte a implementação de um Processo de Planejamento de Vendas e Operações e testá-la através de sua aplicação prática numa Divisão de Negócios que atende o mercado de consumo a partir de uma manufatura de produção para estoque. Identifica os fatores relevantes para uma implementação de sucesso, abordando os três elementos básicos do S&OP: i) Pessoas - Uma vez que o processo é gerenciado e operacionalizado por pessoas, estas precisam estar conscientes, treinadas, além de entender o que se espera delas. Precisam, também, operar o processo em conformidade com os princípios aprovados, políticas e procedimentos; ii) Processo - Um processo precisa estar formalizado, com etapas, entradas, saídas, definição de responsabilidades e de medidas de desempenho; iii) Ferramentas - Devem estar disponíveis para suportar as pessoas na execução de suas atividades. Podem incluir hardware, software, manuais e sistemas de comunicação. O trabalho aborda, também, os potenciais benefícios de um processo eficaz de S&OP, bem como suas limitações, demonstrando a melhoria do trabalho em equipe, do serviço aos clientes e da gestão de ativos, obtidos pela implementação do processo na Divisão de Negócio analisada / Abstract: Sales and Operations Planning is an integrated business management process to generate competitive advantage by looking forward, understanding future scenarios and involving a multifunctional team to define and execute a set of operational plans, aligned to maximize the business results and best attend the customers. This project aims to present a methodology to support a Sales and Operations Planning Process implementation and test it through a practical application in Business Division that attends consumer market through make to stock manufacturing. Identifies the relevant factors to a well succeeded implementation, covering S&OP basic elements: i) People - Whatever is a process managed and operated by people, they need to be acknowledgeable, trained and understand what is expected of them. They also need to operate the process in accordance with agreed-upon principles, policies and procedures; ii) Process - A process needs to be formalized, defining process steps, inputs, outputs, roles, responsibilities, and measurements; iii) Tools - Need to be available allowing people to fulfill their part in the process. These tools may include hardware, software, manual and communication systems. This project also wants to discuss Sales and Operations Planning potential benefits and limitations, demonstrating the improvements the Business Division achieved related to teamwork, customer service and asset management, due to the S&OP process implementation / Mestrado / Planejamento e Gestão Estrategica da Manufatura / Mestre em Engenharia Mecânica

Orientador: Oswaldo Luis Agostinho / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-14T09:48:29Z (GMT). No. of bitstreams: 1 Perdigao_FabianoMarques_M.pdf: 1243627 bytes, checksum: a069968ef5e4e70026b43aa882ecf238 (MD5) Previous issue date: 2009 / Resumo: Este estudo procura constatar e analisar os perfis da gestão de manutenção encontrados nas organizações. Por outro lado, verifica quais componentes do fluxo dos processos de manutenção são impactados pela inovação tecnológica, estratégias de negócios e de manufatura. Para alcançar este objetivo foi proposta uma metodologia exploratória com três dimensões S1, S2 e S3, com oito variáveis distribuídas em cinco atributos A1, B2, C3, D4 e E5, que servem para referenciar o posicionamento das organizações com relação ao controle do processo da gestão de manutenção. Aplicou-se a proposta em três empresas através de entrevistas e questionários, sendo uma do setor de serviços, outra do setor de transportes e a terceira de manufatura. Os dados confiados ao autor não são de domínio público. Após a análise dos dados coletados e a simulação, percebeu-se que as capacitações geradas pelo processo de controle da gestão de manutenção formam uma base para tomada de decisões quanto ao posicionamento estratégico, à manufatura e aos negócios. O resultado final da pesquisa indica que os gestores de manutenção demonstraram algumas dificuldades para elaborar um plano de ação para a manutenção, principalmente por se distanciarem dos problemas operacionais. Observou-se que as alterações nos processos de controle da gestão de manutenção estão direcionadas para a adequação de custos, enquanto o desenvolvimento de novos processos de manutenção não possui um processo estruturado, limitando-se à habilidade dos manutentores. / Abstract: This study aims to observe and analyze the maintenance management profiles found in organizations. On the other hand, it verifies which components of the maintenance processes flow are impacted by technological innovation, business strategy and manufacturing. To achieve this goal, a methodology was proposed to explore three dimensions S1, S2 and S3, with eight variables divided into five attributes A1, B2, C3, D4 and E5, used to reference the positioning of organizations regarding the maintenance management process control. The proposal was applied to three companies through interviews and questionnaires. One of them works in the services sector, another in the transport sector, and the third one in manufacturing. The data entrusted to the author are not public domain. After analyzing the collected data and simulation, it was noticed that the skills generated by the maintenance management process control. formed a basis for making decisions about strategic positioning, manufacturing, and businesses. The research's outcome indicates that maintenance managers demonstrated some difficulties in drawing up an action plan for maintenance, especially because of their distance from operational problems. It was observed that changes in control processes of maintenance management are targeted to the costs adaptation, while development of new maintenance procedures do not have a structured process, limited just to the maintainers' skill. / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica

Variations can have substantially negative effects on performance and it is therefore important to investigate how the variations can be reduced or absorbed in an appropriate way for competitiveness. Manufacturing companies are daily exposed to variations and operations managers need to take capacity management decisions with this in mind to secure the delivery capability. The current body of knowledge mainly focus on techniques for root cause analysis for reducing variations, especially in the manufacturing processes, neglecting the fact that both internally and externally generated variations are more or less possible to affect. Buffers are traditionally associated with waste and unfavourable performance, while the right buffers can be of strategic importance. The purpose of this research is therefore to increase the understanding of causes for variations, actions to reduce variations and how buffers can be used to mitigate negative effects of variations related to capacity management in a manufacturing context. Three research studies have been conducted, including four appended papers, to fulfil the purpose. These studies encompassed different combinations of traditional literature reviews, conceptual research with logical reasoning and case study research. The findings demonstrate that working on mitigating negative effects of variations is a complex challenge and not just about choosing to reduce or absorb the variations. In general, it is concluded that the variation management and buffer management include several aspects to consider with implications for the capacity management. In addition, the results indicate that the decisions in manufacturing companies tend to be based on intuition and previous experience due to a lack of decision support. Furthermore, the participating companies perceive that several of their internal routines contribute to their prevailing variations. This research contributes to an awareness of causes for variations that are possible to affect, possible actions to reduce the variations and the purposes of different buffers to absorb variations. This is sought to facilitate a systematic way of working with reducing and absorbing variations, creating support in the variation management and the buffer management from a capacity management perspective. / Variationer kan medföra negativa effekter för en verksamhets prestation och det är därmed viktigt att utforska hur variationerna kan reduceras eller absorberas på lämpligt sätt för att verksamheten ska vara konkurrenskraftig. Tillverkande företag är dagligen exponerade för variationer och produktionschefer behöver beakta detta i kapacitetsadministrationen för att säkerställa leveransförmågan. Befintlig litteratur fokuserar främst på tekniker för att analysera grundorsaker inom tillverkningsprocesserna och ignorerar det faktum att både internt och externt genererade variationer är mer eller mindre påverkbara. Buffertar associeras traditionellt med oönskat slöseri fastän rätt buffertar kan vara av strategisk betydelse. Syftet med denna forskning är därmed att öka förståelsen för orsaker till variationer, åtgärder för att reducera variationer och hur buffertar kan tillämpas för att överkomma negativa effekter av variationer i relation till kapacitetsadministration inom en tillverkningskontext. Tre forskningsstudier, innefattande fyra publikationer, har genomförts för att uppfylla syftet. Dessa studier består av en kombination av traditionella litteraturstudier, konceptuell forskning med logiska resonemang och fallstudier i tillverkande företag. Resultaten visar att arbetet med att hantera negativa effekter av variationer är en komplex utmaning som stäcker sig bortom valet av att reducera eller absorbera variationerna. Generellt dras slutsatsen att det är flertalet aspekter att beakta för variationsadministration och buffertadministration med implikationer för kapacitetsadministrationen. Det visade sig att besluten tenderar att vara baserat på intuition och erfarenheter i tillverkande företag, mycket till följd av en avsaknad av beslutsstöd. Vidare framgår det att de medverkande företagen upplever att flera av deras interna rutiner bidrar till upphovet av variationer. Denna forskning bidrar till en ökad medvetenhet om orsaker till variationer som är påverkbara inom företag, möjliga åtgärder för att reducera variationerna och syftet med olika buffertar för att absorbera variationer. Detta är avsett att underlätta ett systematiskt arbetssätt för att reducera och absorbera variationer, samt utgöra ett stöd för variationsadministration och buffertadministration från ett kapacitetsadministrationsperspektiv. / KOPability

"This research is aimed at studying the key technologies of Computer-Aided Manufacturing Planning (CAMP) of mass customization for non-rotational part production. The main goal of the CAMP is to rapidly generate manufacturing plans by using of the best-of-practice (BOP) provided by specific companies. A systematic information modeling hierarchy is proposed to facilitate changes in manufacturing plans according to changes in part design. The Object-oriented Systems Analysis (OSA) approach is used to represent information relationships and associativities in the CAMP. A feature-based part information model, a process model, a setup planning model, and manufacturing resource capability models are established. A three-level decision-making mechanism is proposed for the CAMP. At the feature- level, combined features are defined based on part families, and a process model is proposed to describe the information associativities between features and their manufacturing strategies, which include customized cutters and toolpaths. At the part level, graph-based setup planning is carried out by tolerance analysis and manufacturing resource capability analysis. At the machine level, multi-part fixtures are utilized to pursue high productivity. Cycle time is used to evaluate manufacturing plans. Computer software for the CAMP has been developed and integrated with CAD package Unigraphs. The BOP of part families is stored in XML format, which has good extendibility and can be read and edited by standard browsers."

During the manufacturing planning, multiple variants of process chains for the manufacturing of a product to be developed are generated by engineers. In order to select an optimal variant, multiple decision criteria specifying technical, ecological and economical properties of the process chains as well as multiple assessments of different domain experts have to be taken into account. The contribution of this article is a two-step approach that provides a multi-criteria multi-expert assessment of manufacturing process chains supporting the selection of an optimal process chain. A web-based software tool that implements the multi-criteria assessment of process chains is also presented.

The thesis deals with production planning. It contains theoretical description of methods used for production planning and optimizing. Thesis describes bottleneck problems in production. It offers overview of ways to identify and analyze bottleneck influence to manufacturing process efficiency. Thesis proposes ways to eliminate bottlenecks using various algorithm types. It applies theoretical knowledges from optimization and graph theory to program creation that is focused on order delay and readjustment time minimizing. The program implements genetic algorithm.

During the manufacturing planning, multiple variants of process chains for the manufacturing of a product to be developed are generated by engineers. In order to select an optimal variant, multiple decision criteria specifying technical, ecological and economical properties of the process chains as well as multiple assessments of different domain experts have to be taken into account. The contribution of this article is a two-step approach that provides a multi-criteria multi-expert assessment of manufacturing process chains supporting the selection of an optimal process chain. A web-based software tool that implements the multi-criteria assessment of process chains is also presented.