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No. of bitstreams: 1 TeseLLLN.pdf: 5979682 bytes, checksum: 33c85f24ff1e44060833272e3c346492 (MD5) Previous issue date: 2016-12-13 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / The objectives of this thesis were to identify the path of implementation of lean practices in the manufacturing industry located in a region of scarce resources from a developing country, to evaluate the insertion degree such means according certain control variables (company size, industrial sector and the main productive typology) as well as to evaluate the effects of the lean manufacturing implementation on the performance of the companies studied. By means of a Survey, it was possible to investigate the lean manufacturing implementation using robust statistical techniques to define the measurement model defined as the mean of lean manufacturing adoption by the industry researched and to evaluate the effect of such adoption on performance. The results show a high, but partial, degree of lean adoption, which is observed by the identification of its implementation path composed of six internal practices (Single-Minute Exchange of Dies, Human Resource Management, Continuous Flow, Total Productive Maintenance, and Statistical Process Control) and two external (Supplier feedback and Customer engagement). Two other important lean practices (Just In Time delivery and Supplier development) have not been implemented, probably due to the region and country characteristics in where the companies are located such as: remote suppliers and lack of transport/logistics infrastructure plus the great territorial extension. In addition, such adoption has occurred in a fragmented way, as from 36 operational measures that comprise the eight practices considered as the lean implementation path, 13 have not been implemented. Moreover, it was verified the degree of adoption of the lean practices changes according to the company’s size (bigger companies tend to incorporate more practices compared to smaller companies) and the industrial sector. However, there has been no variation in the degree of adoption considering the main productive typology. Finally, it was observed the Lean Manufacturing interrelationship model has a positive effect on operational, financial and environmental performances. / Os objetivos desta tese foram identificar o caminho de implementação de práticas Lean na indústria manufatureira localizada em uma região de recursos escassos de um país em desenvolvimento, avaliar o grau de adoção de tais práticas conforme determinadas variáveis de controle (tamanho da empresa, setor industrial e tipologia produtiva principal) e avaliar o efeito da implementação de Lean Manufacturing no desempenho das empresas pesquisadas. Por meio de um Survey, foi possível investigar a implementação da manufatura enxuta com o uso de técnicas estatísticas robustas para definição do modelo de mensuração estabelecido como o caminho de adoção da manufatura enxuta pela indústria pesquisada e avaliar o efeito de tal adoção no desempenho empresarial. Os resultados mostram um elevado grau de adoção do Lean, porém de forma parcial, evidenciada pela identificação do seu caminho de implementação, composto por seis práticas internas (troca rápida de ferramentas, gestão de recursos humanos, fluxo contínuo, manutenção produtiva total, processo puxado e controle estatístico do processo) e duas externas (feedback de fornecedor e envolvimento de cliente). Além disso, duas importantes práticas Lean (fornecimento Just In Time e desenvolvimento de fornecedores) não vem sendo implementadas, provavelmente em função das características da região do país onde as empresas estão inseridas, a saber: fornecedores distantes e falta de infraestrutura de transporte/logística somada a grande extensão territorial da região estudada. Além disso, tal implementação tem ocorrido de forma fragmentada, visto que dentre as 36 medidas operacionais que compreendem as oito práticas consideradas como o caminho de implantação do Lean, 13 não foram implementadas. Verificou-se também que o grau de adoção das práticas Lean muda conforme o tamanho das empresas (empresas maiores tendem a implementar mais práticas comparada às empresas menores) e o setor industrial. Entretanto, não houve variação no grau de adoção conforme a tipologia produtiva principal. Por fim, observou-se que o modelo estrutural de inter-relação de Lean Manufacturing, apresenta efeito positivo sobre o desempenho empresarial nos âmbitos operacional, financeiro e ambiental.

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This study consists of two studies around Lean. The studies are limited to two databases and three different sectors, the industry sector where Lean originated from, and the welfare and service sectors. The first study is a quantitative pilot study on published articles. The purpose was to get an understanding of what extent the different sectors get published, compared to each other. The result was illustrated in a graph where 40 articles per year were proportionally divided between the three sectors. The main study is a literature review where a scoring matrix was used to cull the selected articles. The remaining articles where compared to the “Toyota house” to answer the research questions: In what way has the definition of Lean changed from the manufacturing-based improvement philosophy it originated as, to the concept that is used in different sectors today? How does the specific sector affect the implementation of Lean, is there a difference in the Lean that is described in the literature compared to the Lean that is used in the welfare or service sectors? The study found in the chosen literature is that the sectors that are new at using Lean are using less of the tools available and in a smaller part of the organization, instead of using it on the whole organization. Many case studies where found that describes what tool was used, but not how they were used. One sector with many published articles was the construction sector, but they were overlooked due to the limitations of the study. / Denna studie består av två undersökningar kring Lean. Undersökningarna är begränsade till två databaser samt tre branscher, industribranschen där Lean grundades samt välfärds- och tjänstebranschen. Först gjordes en kvantitativ förstudie av publicerade artiklar för att få en uppfattning kring hur många andelar av de olika branscherna artiklarna bestod av. Resultatet visades i form av en graf där 40 artiklar från varje år delades upp i de tre branscherna. Efter det gjordes en litteraturstudie med en bedömningsmatris för en utgallring av artiklar. Utvalda artiklar jämfördes därefter mot ”toyotahuset” för att svara på forskningsfrågorna: På vilket sätt har definitionen av Lean förändrats från den produktionsbaserade förbättringsfilosofin det ursprungligen var, till det uttryck som används i flera olika branscher idag? Hur påverkar branschen implementeringen av Lean, skiljer sig det Lean som beskrivs i litteraturen mot det Lean som används i välfärds- eller tjänstesektorn? Det vi kunde hitta i den utvalda litteraturen var att de branscher som är nya med Lean använder färre verktyg och på mindre delar av sin organisation istället för att göra implementeringen på hela organisationen. Vi hittade många ”case studies” som berättar att det använt verktyg men inte hur verktygen har använts. En bransch som det hittades mycket artiklar om men som sållades bort på grund av avgränsningen var Lean construction.

Productivity of automotive manufacturing production systems have been an area of study among researchers since the industrial revolution. Automotive manufacturing production systems that are implemented properly increase productivity in production environments. Researchers have demonstrated that productivity can be improved through modeling the Toyota production system. However, researchers have not established how implementing Mercedes Benz production system (MBPS) impacted Mercedes-Benz cars' productivity between 1999 and 2017. The purpose of this quantitative research study was to examine the effect of implementing the Mercedes-Benz Production System (MBPS). A survey was administered to 35 Mercedes-Benz employees that consisted of operation managers, plant managers, manufacturing engineers, and shop workers. The study used Spearman's correlations to analyze the strength of the associations between the dependent variable of productivity and the three independent variables of cycle-time variation, employee-headcount variation, and key performance indicators. The results showed no statistically significant relationship, supporting that implementing the MBPS was not sufficient enough to reject the null hypothesis the research questions. The social change implications for this research may promote positive social change by its emphasis on the implementation of manufacturing production systems. Such implementations may then stimulate increased economic efficiencies, quality, and profitability for society.

Inom byggbranschen är det av vikt att hitta arbetssätt som på lång sikt sänker byggkostnaderna för att på så sätt kunna producera en vara som kräver mindre förbrukning av resurser men som även fortsätter vara konkurrenskraftig. Syftet med detta examensarbete är att undersöka hur medarbetarna vid Skanskas byggprojekt "Trädgårdarna" i Boglundsängen, Örebro kommun, arbetar för att minimera slöserier (icke värdeskapande aktiviteter). Syftet är även att identifiera vanliga slöserier som förekommer, både generellt på byggarbetsplatser men i synnerhet på byggprojektet "Trädgårdarna", samt att slutligen komma med förslag på åtgärder för att mini-mera dessa slöserier. Arbetet grundar sig på en kvalitativ metod i form av intervjuer och obser-vationer. När detta arbete skrevs var produktionen i ett tidigt stadie. Arbetets resultat påvisar att det finns både styrkor och brister gällande hur arbetet på "Trädgårdarna" fortskrider. Även fast produktionen i skrivandets stund inte har kommit så långt på projektet framkommer det av resultatet att personalen värdesätter ordning och reda och försöker upprätthålla detta genom olika tillvägagångssätt. Överlag arbetar personalen bra med att minska slöserier på arbets-platsen. De slöserier som har uppstått beror främst på brister i projekteringen och/eller produktionsplaneringen. För att minska slöserierna och upprätthålla ett effektivt arbetssätt är det av stor vikt att ha en genomarbetad projektering, genomföra arbetsberedningar på så många moment som möjligt, ha god ordning och reda på arbetsplatsen, ta tillvara på personalens kunskap och engagemang samt att utnyttja någon form av samordnad leverans för att minimera lagerhållningen och väntetiderna. / In the construction industry it is important to find ways of working that in the long term lowers construction costs so as to produce a product that requires less consumption of resources, but which also continues to be competitive. The purpose of this thesis is to investigate how employees at Skanska's construction project "Trädgårdarna" in Boglundsängen, Örebro, work to minimize wastes (non value-adding activities). It also seeks to identify common wastes that occur, both generally on construction sites but in particular on the building project "Trädgårdarna", and finally to come up with suggestions on measures to minimize these wastes. This thesis is based on a qualitative method in the form of interviews and observations. When this thesis was written production was at an early stage. The results of this thesis demonstrate that there are both strengths and weaknesses regarding how work on "Trädgårdarna" is pro-gressing. Although the production was in an early stage, during the time of writing this thesis, the results show that the staff appreciates orderliness at their workplace and try to maintain this through different means. Overall, the staff work well to reduce wastage in the workplace. The wastes which have arisen primarily did so due to deficiencies in the design and/or production planning. To reduce the wastage rate and maintain an effective work it is of great importance to have a well-planned design, to implement work preparations as frequently as possible, to have an orderly workplace, to take advantage of the staff's knowledge and commitment and to use some form of coordinated delivery system to minimize inventory and waiting times.

Syfte: Branschen tampas fortfarande med kvalitetsbrister och har därför börjat uppmärksamma de fördelar som följer med industriellt byggande och standardiserade arbetsprocesser. Med industriella arbetsprocesser kan företagen ge frihet till arbetare att få ansvara för de arbetsprocesser som de medverkar i, och således bidra till att de förbättrar lösningar och standardiseringar. Ett koncept som lämpar sig väldigt väl för detta är The Toyota Production system (TPS), också kallat Lean production. År 2016 utfördes en samling fallstudier bland Lean-arbetande byggföretag där de visade att kvalitet och strävan efter standardiserade arbetsprocesser var högt prioriterat. Lean production och dess processer i företag omfattar informations – och kunskapsöverföringar och kan vara svårt att tillämpa. Därför motiveras vidare forskning på tillämpbarheten av principerna och dess verktyg i byggföretag. Studiens mål är att analysera hur företag inom prefabindustrin som arbetar med Lean kan utveckla sitt förbättringsarbete i produktionsprocessen. Metod: Rapporten är en kvalitativ fallstudie utförd på Ulricehamns Betong AB. Studiens datainsamlingsmetoder har varit litteraturstudier, deltagande observationer, semistrukturerade intervjuer och dokumentanalyser. Resultat: Utifrån studiens analys kunde vissa problem i förbättringsarbetet identifieras, samt leda till en analys över hur det förbättras och göras mer kunskapsdelande. Det framkom att inställningen till förbättringsarbete varierade stort bland medarbetarna. En gemensam syn på förbättringsarbetets betydelse krävs för fortsatt utveckling, något som kan uppmuntras från organisationens håll tydligare. Genom rollen som handledare kan företag säkra att det arbetas efter standardiserade arbetssätt. Konsekvenser: Avgörande för ett kunskapsdelande och utvecklande förbättringsarbete är att alla medarbetare är motiverade till att bidra till en förbättring. För att motivera medarbetarna bör statusen på individuell kunskap följt av inställning till kunskapsdelande att höjas. Medarbetare ska ha tillgång till kontinuerliga förbättringsmöten eller andra forum där de kan utbyta erfarenheter och idéer. Begränsningar: Fallstudien har genomförts på ett företag som använder sig av Lean-konceptet. Studien begränsas till att endast behandla förbättringsarbete i produktionen av prefabricerade betongelement.  Studien redogör alltså inte för hur andra prefab-företags förbättringsprocesser ser ut i produktionen. / Purpose: The industry is still struggling with reoccurring deficits regarding quality and has therefore began to pay attention what benefits that comes with an industrial building process. With industrial building processes the companies using it can let the workers be in charge of their work processes that they find themselves in and thus help to improve and standardise them. A concept that fits these conditions very well is The Toyota production system (TPS), also known as Lean production. In the year 2016 several studies were made that showed that among Lean working construction companies it was the reach for higher quality and standardised working processes that was prioritized. Lean production and its processes contains a lot of information- and knowledge transfers and may be hard to practice in a company. Therefore further studies on how to implement these principles and tools properly are recommended. The aim with this study is to analyse how companies in the precast industry who works with Lean can evolve their continuous improvement process in the production process.   Method: This report is a qualitative case study accomplished at Ulricehamns Betong AB. The chosen methods on how to collect data are literature studies, participating observations, semi-structured interviews and document analysis. Findings: From the analysis of this study some problems in the improvement process could be identified, but also how they could be improved and how they could be more knowledge sharing. It was shown that the will to participate in the improvement process did varied a lot among the co-workers. A common attitude for the importance of the improvement process is needed for the continuous development, something that can be more encouraged by the organisation. Through the implementation of a mentor the company can ensure that the production process is more standardised. Implications: The number one thing that is most important for an evolving and knowledge sharing improvement process is that the co-workers stay motivated to participate. To motivate them, the status of individual knowledge should be raised and heard. Furthermore they should have access to continuous improvement meetings or other forums where they can exchange experiences and ideas. Limitations: The case study has been accomplished at a company that are using the Lean concept. The study limits to only study the improvement process in the production process of precast concrete elements. Furthermore the study is focused on how one specific company uses their improvement process and not how other companies uses theirs.

In product manufacturing, assembly approximately represents 50% of the total work hours. Therefore, an efficient and fast assembly system is crucial to get competitive advantages at the global market and have the right product quality. Today, the verification of the assembly system is mostly done by utilizing software based simulation tools even though limitations have been identified. The purpose of this thesis is to identify when the use of additive manufacturing technology could be used in assessing the feasibility of the assembly system design. The research questions were threefold. First, identifying limitations that are connected with the used assembly simulation tools. Secondly, to investigate when additive manufacturing can act as a complement to these assembly simulations. Finally, to develop a framework that will assist the decision makers when to use additive manufacturing as a complement to assembly simulations. The researchers used the method of case study combined with a literature review. The case study collected data from semi-structured interviews, which formed the major portion of the empirical findings. Observations in a final assembly line and the additive manufacturing workshop provided valuable insights into the complexity of assembly systems and additive manufacturing technologies. In addition, document studies of the used visualization software at the case company resulted in an enhanced understanding of the current setting. The case study findings validate the limitations with assembly simulations described in theory. The most frequent ones are related to visibility, positioning, forces needed for the assembly operator, and accessibility between different parts. As both theory and case study findings are consistent in this respect, simulation engineers should be conscious of when to find other methods than simulation for designing the assembly system. One such alternative method is the utilization of additive manufacturing. The thesis outlines a number of situations where additive manufacturing indeed could act as a complement to assembly simulation. The authors argue that the results and findings to a large degree are applicable to other industries as the automotive sector is very global and competitive in nature and encompasses a large variety of complex assembly operations. A structured framework was also developed that could act as a decision support. The framework takes into account three dimensions that are crucial for the decision; (1) the assembly simulation limitation, (2) the context of the assembly and which parts are involved and (3) the possible limitations of additive manufacturing in the specific context. This impartial decision framework could help companies with complex assembly systems to know when to use additive manufacturing, as well as for which parts and subparts additive manufacturing is applicable. To increase the longevity of the decision framework, new improvements of assembly simulation tools and additive manufacturing technologies, respectively, should be incorporated in the framework.

The subject matter of this paper is a comparative review of egg production systems for theircontribution to sustainable development of egg production in order to assess the perceived challenges of eggfarmers in Germany. The thesis features a case study which presents two farms located in Germany, andimplementing different farming methods. The floor-range farming method and the organic system illustrate thisexample. The methodological approach is based on a three-phase framework, in which significant issuesconcerning sustainable development are presented (Phase 1), the significant issues are translated into sustainableindicators (Phase 2), and the contribution of sustainable indicators to sustainable development is assessed (Phase3). Phase 1 and 2 build on an extensive literature review and farmers consultation. Phase 3 relies on numericalcomparisons. A comparative analysis of the empirical data is based on theories and the developed conceptualframework. Based on the comparison of two specific farms, the results of this work indicate that the organicfarming system reveals the least negative contribution to sustainable development of egg production in Germany.The floor-range farming system shows a slightly more negative contribution to sustainable developmentcompared with the organic EPS. The organic farming system, therefore, is considered the better animal-friendlysystem. It is certainly noteworthy to mention that the organic system however fail to contribute to sustainabledevelopment from an economic perspective. Thus, the main perceived challenge for the organic farmer is tooperate his organic business in a more profitable way. The floor-range system on the other hand, succeeds tocontribute to sustainable development in economic terms, but fails to contribute positively from an ecologicaland social perspective. Therefore, the farmer operating the floor-range EPS needs to improve the ecological aswell as social conditions on his farm in order to achieve an equal positive contribution to sustainabledevelopment.

This work focuses on the issues related to improving the manufacturing process effectiveness in the company Boltjes International spol. s r.o, based on the principles of lean manufacturing. It mainly comes out from the theoretical principles of the Toyota Production System. Based on the analysis of the organisation of the manufacturing system of the company Boltjes the graduation theses describes problematic areas. The paper establishes their priorities and submits practical proposals and recommended solutions in the direction of higher productivity of the complete manufacturing process. The paper uses for these solutions a method of a qualified significance tree and the mapping of the manufacturing flows. The paper deals with stock management, organisation of the manufacturing system and with management of human resources.

I denna rapport med titeln Lean production system-Implementering av produktionssystem samt dess hinder utifrån ett organisatoriskt perspektiv, granskas kategorierna organisationsteori och Lean production system inom ramen för rapportens studie av ett fordonstillverkande företag. Specifikt ligger fokus på organisationskulturer, konflikter och motivationsteorier, men även utvecklings- och förbättringsprocesser, olika typer av slöserier som frekvent dyker upp och ledarskap ägnas uppmärksamhet med avseende på att skapa en djupare förståelse för hur en befintlig organisationskultur påverkas vid implementering av Lean production system och hur slöserier kan uppstå.   En av rapportens intentioner är att beskriva och analysera varför organisationer som implementerar och genomför Lean production system och integrerar detta i det egna produktionssystemet, kan uppleva svårigheter och medverka till att organisationer inte uppnår sina fulla potentialer. Föreliggande rapport använder som exempel i denna framställning företaget Volvo Cars i Göteborg som kategoriseras som en Lean hybrid. En Lean hybrid är företag som implementerat Lean production system med sitt egna produktionssystem och följer de principer Lean production system förespråkar. En viktig aspekt som underbygger syftet är att kunna beskriva de konsekvenser som sannolikt blir följden då organisationer inte anpassar strukturerna i sina produktionssystem efter vad Lean production system förespråkar om gällande förbättringsarbeten och arbetet mot att eliminera slöserier. Omvänt innebär detta att om befintliga produktionssystemen följer vissa principer och premisser, ska de verktyg och metoder som Lean production system erbjuder, vara giltiga och effektiva i målet att förbättra och förenkla  Syftet med rapporten var att undersöka varför organisationer med befintliga produktionssystem stöter på hinder och problem med att implementera och genomföra Lean production system i sina organisationer, samt hur stort inflytande organisationskultur och förhållningssätt har i denna process.  Rapportens metodansats utgörs av kvalitativa och kvantitativa metoder med tyngdpunkt på kvalitativ metod. En litteraturstudie har genomförts via de databaser som högskolan erbjuder. Insamling av data har skett genom observation, intervjuer och simuleringar för att få ett helhetsperspektiv på nuläget i Volvo Cars i Göteborg.   Rapportens resultat visar att en specifik organisationskultur kan medverka till att produktionsnedsättande faktorer som slöserier, tröghet i information och instruktion flödet, subkulturer, konflikter och bristande motivation skapas eller fortsätter att existera, men pekar också på vikten av att en organisationskulturs policy bör gestaltas på alla nivåer i en organisationsstruk- 2 -  tur. Problem och hinder kan således skapas och uppstå när det saknas en gemensam värdegrund för ledarskap, utbildning och kompetensutveckling. En konsekvens av detta är att produktionsnedsättande faktorer tenderar att bäddas in i redan befintliga och standardiserade rutiner, där förbättringsarbeten paradoxalt nog skapar en negativ utveckling av produktionsprocesser och med tiden utvecklas till typ-II slöserier. / In this report entitled Lean production system- Implementation of Lean as well as its obstacles from an organizational perspective, the categories of organization theory and Lean production system are examined in the context of the report's study of a vehicle-making company. Specifically, the focus is on organizational cultures, conflicts and motivational theories, but also development and improvement processes, different types of waste and leadership. Attention is given to creating a deeper understanding of how an existing organizational culture is influenced by implementation of Lean production systems and how wastes can occur.  One of the intentions of the report is to describe and analyze why organizations that implement and carry out Lean production systems and integrate this into their own production system can experience difficulties and help organizations not achieve their full potentials. The present report uses, for example, in this study the company Volvo Cars in Gothenburg, categorized as a Lean hybrid. A Lean hybrid is a company that implemented Lean production system with its own production system and adheres to the principles lean pro duction system advocates. An important aspect that underpins the purpose isto be able to describe the consequences that are likely to be followed when organizations do not adapt the structures in their production systems according to the Lean production system and what it advocates on continuous improvement efforts and efforts to eliminate waste. Conversely, this means that if existing production systems following certain principles and premises, the tools and methods provided by the Lean production system should be valid and effective in the goal of improving and simplifying.  The purpose of the report was to investigate why organizations with existing production systems encounter obstacles and problems in implementing and carrying through Lean production systems in their organizations, as well as the influence of organizational culture and approaches in this process.   The method of assessment of the report consists of qualitative and quantitative methods with a focus on qualitative methodology. A literature study has been conducted through the databases offered by the university. Data collection has been through observation, interviews and simulations to get a full-view perspective at the current moment in Volvo Cars in Gothenburg.  The report's results show that a specific organizational culture can contribute to the creation or continuation of production-reducing factors such as waste, inertia in information & instruction flow, subcultures, conflicts and lack of motivation. However, it also emphasizes the importance of organizational culture policy being embodied at all levels in an organizational structure. Problems and obstacles can thus be created and arise when there is no common value base for leadership, education and competence development. One consequence of this is that production-lowering factors tend to be embedded in existing and standardized practices, where improvement efforts paradoxically create a negative development of production processes and eventually develop into Type II wastes.