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

Background: The demand for sending letters, in the traditional aspect, has decreased because of electronic sources which have replaced a big part of letter communication. The Postal Service constantly strives for lowering costs and due to the changeable demand, a greater awareness is required regarding recourses and their usage. The previously mentioned measures in combination with commonly occurring quality issues during the collective process at the letter terminal in Alvesta would be improved by applying a lean-perspective to the process. A first step towards saving of time is to apply the “value stream mapping”-method on the collective process for small and large letters. Purpose: To map the process of collection for small and large letters to be able to identify waste of recourses and furthermore give suggestions on how the Postal Service would be able to reduce the waste of recourses identified. Moreover, the purpose is also to illustrate the process of collection, following a reduced waste of recourses, to give the Postal Service an opportunity to obtain saving of time. Method: The report consists of a qualitative case study on the Postal Service’s letter terminal in Alvesta. Data collection has been conducted by literary studying, direct observation and semi structured interviews. Conclusions: Several results have shown in the report, such as the fact that a waste of recourses has been identified in all activities involved in the process of collection. Furthermore, actions have been suggested to reduce the occurring waste in the form of standardized guide lines, reorganization of equipment, working towards a continuous flow and the introduction of numerous flexible workers within the process. How the process of collection for small and large letters can be designed after a decreased waste of resources is illustrated to give the Postal Services a vision to strive for as well as an opportunity to obtain saving of time.

Bakgrund: Att utveckla och förbättra organisationer genom effektivare användning av de resurser man har till förfogandet har blivit allt mer betydelsefullt under de senaste decennierna. Genom fokusering kring de aktiviteter som tillför värde hos kunden i slutprodukten kan företag reducera och eliminera oönskade slöserier inom tillverkningsprocessen. Ett verktyg som utvecklats och används för att eliminera dessa oönskade aktiviteter så som lagerhållning är Value stream mapping (VSM).   Problemformulering: Hur kan man identifiera slöserier samt dess förbättringsmöjligheter för att möjliggöra en högre produktionskapacitet genom frigörandet av anläggningsyta?¨   Syfte: Genom användandet av VSM som modell, identifiera slöserier och kostnadseffektiva förbättringsmöjligheter.   Metod: Denna fallstudie har utförts på ett företag som arbetar inom metallindustrin. Större delen av datainsamlingen har tagits från företagets egna dokumenterande data samt intervjuer med anställda och observationer under de besök författarna genomförde.   Slutsatser: Genom att använda VSM som en modell har författarna lyckats identifiera fallföretagets största faktorer till slöserier samt ge förslag och underlag till framtida förbättrings implementationer av förbättringsstrategier. Författarna har bevisat utifrån den teoretiska data studien är grundad på gentemot den empiriska att flertal förbättringsmöjligheter utöver den som företaget tänkt sig finns till deras förfogande vid eventuell framtida implementering.   Nyckelord Value stream mapping, VSM, slöseri, materialflöde, materialhantering, tillverkningsindustri, förbättringsstrategi

Med utgångspunkten att ständigt förbättras och öka konkurrenskraften arbetar Alfa Laval mot Leanprinciper. Vad som dock är ett problemområde är att se över fabriken ur ett helhetsperspektiv, närfabriken är uppdelad i många avdelningar. Lösningen till detta problem är att via olika metoder ellerverktyg kunna fastställa svaren på problemen.Denna examensrapport redogör för hur metoder inom Lean produktion kan vara lösningen förproblemområdet. Forskningen är huvudsakligen byggd på en bred värdeflödesanalys som syftar till attfånga in ett företags alla aspekter ur ett helhetsperspektiv, med syftet att minska risker försuboptimering och istället optimera produktionen som helhet.För att se gränssnitt mellan informationsflödet har i denna forskning metoden swimlane utgjort enkartläggning över ett företags hela kontorsavdelning, planerings och inköps avdelningar.Resultatet av denna forskning visar att värdeflödesanals är en bra metod för att kunna identifieraslöserier, ojämnheter i produktion, brister vid tillverkningen och flaskhalsar. För att sammankopplaolika avdelningar av ett företags informationsflöde, visas i resultaten att swimlane är en bra metod försyftet.

This thesis analyzes and argues how implementing lean principles and tools affect an organization’s architectural innovation. Introducing new product architectures and modifying existing architectures is often difficult for companies. Architectural innovation requires extensive company resources for experimentations and new learning.    Applying lean principles and tools in an  innovative organization often make difficulties since innovation focus on active exploration for new solutions within a constantly changing environment (high risks). Whereas, lean focus on eliminating all kind of waste in the system (low risks). Little is known about how lean principles and tools might affect architectural innovation in organizations. Therefore, this research explores the relationship between lean and architectural innovation in manufacturing industries. The data sample use for this study is Swedish manufacturing companies in seventeen different industry types.  The types of industries consist on system level product type such as electrical or/and mechanical integrated products.  Results suggest that in lean principles and tools, standardization, value stream and human resource management (HRM) have significantly positive effect on organization’s architectural innovation capability. Whereas, lean design for manufacturability (DFM) has no significant effect on an organization’s architectural innovation capability. This study’s findings suggest companies that have not implemented lean thinking and practices yet can adopt lean concepts not only for efficiently utilizing the resources but for improving the architectural innovation also.  Furthermore, lean companies should increase their focus on customer involvement in product development as well as in cross-functional training of employees and on job training programs to improve the architectural innovation. Findings suggest that those companies that have strategic focus on architectural innovation can adopt lean concepts and procedures from manufacturing and production departments in order to dramatically increase the architectural innovation.

Orientador: Orlando Fontes Lima Júnior / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Civil, Arquitetura e Urbanismo / Made available in DSpace on 2018-08-19T15:05:07Z (GMT). No. of bitstreams: 1 Monteiro_VeraLucia_M.pdf: 6503368 bytes, checksum: 6c3cbfa37d4c6be4c55790c4d7e3a025 (MD5) Previous issue date: 2011 / Resumo: As técnicas do pensamento enxuto ou Lean Thinking têm sido amplamente aplicadas na indústria. Entretanto, elas também têm se mostrado eficazes nas atividades da área da saúde. Sendo assim, este estudo objetivou investigar sua aplicação nas atividades de logística dos transplantes de órgãos sólidos, tentando reduzir seu tempo de ciclo, porque o tempo é a principal e mais importante restrição nos processos de transplante. A pesquisa foi realizada em parceria com a Organização de Procura de Órgãos do Hospital das Clínicas da Universidade Estadual de Campinas. Os procedimentos envolveram o acompanhamento in loco dos processos de transplante escolhidos, desde a retirada do órgão do doador até o seu implante no receptor, tendo sempre por foco as atividades logísticas. Após o mapeamento dos processos, foram feitas análises críticas, buscando detectar os desperdícios em cada etapa e então, um redesenho de processo foi proposto, com vistas a reduzir o seu lead time, através da eliminação dos desperdícios encontrados. Na seqüência, um mapa de valor futuro projetado foi desenhado, representando os processos mais enxutos. Algumas implementações de melhorias sugeridas foram feitas, através da aplicação de ferramentas lean apropriadas a cada situação e, finalmente, um novo processo foi mapeado para comparação dos lead times antes e depois das implementações. Esperou-se com este estudo averiguar a aplicabilidade das técnicas do pensamento enxuto, como capazes de produzir importantes melhorias nos processos da logística de transplantes de órgãos sólidos, assim como vem acontecendo em outras atividades da área da saúde / Abstract: The Lean Thinking Techniques have been widely applied in industries; however they have also been effective in healthcare activities. Thus this study aimed to investigate the use of these techniques in the logistics activities of solid organs transplantation, trying to reduce its cycle time because time is the main and the most important constraint for transplantation operations. The research was developed in partnership with Organ Procurement Organization at the Clinic Hospital in State University of Campinas. The procedures involved the mapping of all logistics activities, into the transplantation processes, from the removal of the organ donor until its transplantation into the recipient. After process mapping, critical analyses were made to look for waste in each stage. Then a process redesign was proposed, trying to reduce the total lead time by reducing waste observed. So a hypothetical future state value stream mapping was drawn representing the processes with less waste. Some improvements were implemented, by applying the appropriate lean tool to the situation observed and finally, a new process was mapped in order to allow the comparison between lead times after and before the implementations. It is hoped this study verify the applicability of the lean thinking techniques as capable of adding important improvements to the logistics processes of solid organs transplantation, following the tendency of other healthcare-related activities / Mestrado / Transportes / Mestre em Engenharia Civil

This Master's thesis is focused on complaint handling process in the chosen enterprise. The main goal of this thesis is optimization of the chosen customers' complaints using the appropriate Six Sigma methods. In the theoretical part the reverse logistics and its importance are described then Lean enterprise concepts and methods, which are used for the complaint handling process optimization, are explained. The first part of the practical part introduces the enterprise and its logistics and complaint handling process. The rest of the thesis contains the complaint handling process optimization using the DMAIC method.

Dagens företag blir allt mer resursbejakande. Ett sätt att bli mer effektiva med resurser är lean production, en strategisk metod som går ut på att eliminera slöseri. Värdeflödesanalys är ett verktyg inom lean som kan användas för att få en klarare bild av hur verkligheten ser ut och hjälpa till att få en klarare bild av vart problemen ligger. När en sådan analys har gjorts upptäcks ofta en maskin eller station som saktar ner produktionen. Sådana stationer kallas ”flaskhalsar”. Syftet med denna studie är att utforma en metodik för analys och effektivisering av materialflöden baserat på flaskhalsteori och lean production. Metodiken testas på Företag AB:s filial. Utifrån litteraturstudier arbetades metodiken fram, den består i huvudsak av två steg, nulägesbeskrivning och analyserande diskussion. Dessa steg sker med stöd av olika faktorer inom lean production och flaskhalsteori. Metodiken tillämpades på vårat fallföretag, och visade sig bl.a. vara ett strukturerat sätt för att studera nuläet och diskutera förbättringsförslag. Litteraturstudier har genomförts för insamling av teori. På företaget genomfördes intervjuer och observationer med personal och chefer som var delaktiga i flödet som studerades, SK23DF. Filialen på Företag AB jobbar med 150 olika stålsorter och ca 3000 olika produkter. Flödet är dessutom korsande och prognosstyrt och det medför att det blir ett massivt undertagande att effektivisera dessa på bästa sätt. Slutsatser som nåtts är att personalens nuvarande samsyn för effektiv produktion är ett hinder för detta. Personalen bör utbildas för att få en större bild av helheten och på så sätt ge dem bättre förutsättningar vid förändring och förbättringsarbete. All forskning pekar på att en god förståelse av nuläget, av samtliga inom organisationen, är nyckeln till ett lyckat förändringsarbete vid effektivisering av flöden. / Companies today are becoming more and more resource-promoting. A way for companies to become more effective with their resources is Lean Production, which is a strategic method that involves eliminating waste. Value stream mapping is a tool that can be used to get a clearer picture of reality and visualize where the problem lies. When the analysis is done, it will often show a machine or station that is slowing down production. Stations like that are called ”bottlenecks”. The purpose with this study is to form a methodology for analysis and efficiency of material flows based on bottleneck theory and lean production. The methodology will be tested on Företag AB:s filial. The methodology was worked out from literature studies. It consists of two main steps, status report and analyzing discussion. These two steps is supported by different factors within lean production and bottleneck theory. The methodology is applied on our business case and showed to be a structured way to study the current state of production and to discuss improvements. Literature studies has been used to gather theoretical knowledge. Within the company interviews and observations were conducted with operators and executives who was involved with the product flow that was investigated, SK23DF. Företag AB:s filial works with 150 different types of steel with about 3000 different products. The production flow is also forecast-controlled and intersecting and it is a massive under-taking to streamline these in the best way possible. Conclusions reached is that the staff's current consensus for efficient production is an obstacle to this. The staff should be trained to get a bigger picture of the whole, thus giving them better prospects for change and improvement. All research points to the importance of fully understanding the current situation, by everyone within the organization. This is the key to succeed with change management at streamlining flows.

El presente proyecto está enfocado en mejorar la productividad de una empresa manufacturera de neumáticos, específicamente la línea de producción de neumáticos radiales, con el fin de poder satisfacer la demanda creciente y no perder valor con sus clientes. Para cumplir con este objetivo, se aplica un modelo basado en los principios de herramientas de Manufactura Esbelta en este trabajo, el cual está estructurado en cinco capítulos. El primer capítulo brinda un marco teórico de las herramientas, técnicas y lineamientos a seguir, basado en el estado del arte, que brinde el know how necesario para poder aplicar correctamente las técnicas y herramientas de Manufactura Esbelta. El capítulo dos nos muestra un diagnóstico general de la empresa, detallando el problema principal que presenta, el impacto en la rentabilidad que este tiene y sus causas. El tercer capítulo se centra en la aplicación de las metodologías explicadas, determinando el proceso restrictivo y aumentando su capacidad (herramientas de Manufactura Esbelta). Tras ello, en el capítulo cuatro, se realiza la validación de la implementación, ejecutado mediante un plan piloto, el cual evidencia una mejora significativa en la productividad de la línea. Luego, en el capítulo cinco, se presenta la medición de los impactos, siendo estos sociales, ambientales, organizacionales, entre otros, que puedan repercutir tras la implementación de las herramientas. Finalmente, se determinan las conclusiones y recomendaciones que se obtienen tras el desarrollo de todo el proyecto. / This project is focused on improving the productivity of a tire manufacturing company, specifically the radial tires line, in order to satisfy the demand and not lose value with customers. To accomplish this objective, a model based on the principles of Lean Manufacturing tools is applied in this assignment, which is structured in five chapters. The first chapter provides a theoretical framework of the tools, techniques and guidelines to follow, based on the state of the art, which provides the necessary knowledge to be able to correctly apply the techniques and tools of Lean Manufacturing. Chapter two shows a general diagnosis of the company, showing the main problem of it, the impact on the profitability that it has and its causes. The third chapter focuses on the application of the methodologies explained yet, defining the restrictive process and increasing its capacity (Lean Manufacturing tools). After that, in chapter four, validation of the implementation is carried out, executed through a pilot plan, which evidences a significant improvement in the line’s productivity. Then, in chapter five, the measurement of impacts is showed, as social, environmental, organizational, among others, that can impact through the implementation of the tools. Finally, conclusions and recommendations that derive from the development of the entire project are determined. / Trabajo de Suficiencia Profesional

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / The printing sector in Peru constantly faces the need to reduce production time because late deliveries to the customer owing to high manufacturing time are critical problems. Previous studies have proposed using the lean manufacturing philosophy to reduce idle times by improving the flow of information within the production processes in large manufacturing companies but not printing SMEs using these tools in a make-to-order environment. This document focuses on implementing an affordable lean manufacturing model in an SME company with a make-to-order environment to reduce its manufacturing times. Therefore, the Kanban, Single Minute Exchange of Dies (SMED), and value stream mapping (VSM) processes will be adapted for implementation in these companies. Then, the model is validated through its application in a case study; through process simulation, production times were reduced by 24% for an SME, delivering all orders on time, and eliminating 100% penalty costs for late orders.