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Increasing global competition, high stumpage and energy prices, and the slowing housing market have challenged the U.S. hardwood lumber industry during the past several years. Many wood product manufactures are trying to remain in business by implementing continuous improvement programs like lean manufacturing. However, the lumber drying process where lumber is kiln-dried in large batches, can significantly increase manufacturing and inventory lead-time; and is a process that tends to limit how lean the remaining process can become. Vacuum drying has the potential to reduce drying times, reduce batch sizes and achieve product quality comparable or superior to conventional drying. The overall goal of this research was to evaluate how vacuum-drying technology could support further lean implementation in manufacturing of hardwood products. Specifically, to estimate conventional and vacuum drying times, quality, and costs for drying 4/4 red oak lumber; to determine by the use of feasibility analysis (cash flow, net present value, and internal rate of return) differences between conventional and vacuum drying for 4/4 red oak lumber; and to determine if the high capital cost of vacuum drying equipment can be justified with the reduction of WIP and cycle time, while meeting desired throughput. The study includes a cost analysis of vacuum and conventional drying, and a determination of the potential financial gains associated with the reduced drying times via vacuum drying. It was determined that vacuum drying quality was equal or better than conventional drying with less checking, end splits, drying stress and shrinkage. Compared to conventional drying, vacuum drying times with air drying and without air drying were 67% less and 70% less, respectively. Conventional and vacuum with no air drying scenarios were determined to be financially feasible when compared using Net Present Value and Internal Rate of Return analysis. However, vacuum drying with no air drying had better NPV and IRR values than conventional drying. The scenario of vacuum with air drying was not feasible. Two case studies, each employing the three drying scenarios (conventional drying, vacuum with air drying, and vacuum without air drying), were used to determine the impact of cycle times and work in process. It was determined that the cycle times for vacuum drying were 87% and 95% less than conventional drying for the first case study and 51% and 90% less than conventional drying for the second. WIP was 48% and 84% less in the first case study and 43% and 92% less than conventional drying for the second. Cycle time was reduced by 87% and 51% for Plant C and D, respectively. Finally it was determined that the reduction of WIP represented a cost saving of 73% and 76% for the two case studies. The reduction in costs, faster drying rates, and equal quality, and reduced cycle times make vacuum drying a potential technology available for improvement of the competitiveness for flooring manufacturers. / Master of Science

This report is the result of a thesis work carried out on the Risifrutti production at the company Procordia Food AB. The thesis is at a master level and is the final work for the author to receive a Master of Science in Innovative production at Mälardalen University. The thesis comprises 30 credits and has lasted for 18 weeks. The thesis is mainly a research on whether it is possible to perform an Environmental Value Stream Map (E-VSM) in a food processing industry and an evaluation if the tools E-VSM and Green Performance Map (GPM) are useful in this type of industry. An extra part to this research is to use the results from the E-VSM and give Procordia Food AB information on improvement potentials in the Risifrutti production. The author has found it difficult to collect some of the quantitative data to the E-VSM, mainly regarding energy, but by using the Value Stream Mapping (VSM) tool and other Lean tools the author was able to identify and quantify several wastes in the Risifrutti production. Recommendations for improvements based on these wastes have been given to the company. In the research part of this report the utility of the Value Stream Map, Environmental Value Stream Map and Green Performance Map in a food processing industry have been analyzed. The author has found that the Value Stream Map has been a useful tool since waste and unevenness in the tact of the production has been identified. The Environmental Value Stream Map and the Green Performance Map are also great tools when a company wants to analyze their environmental impact and then invest in environmental improvements. However, no profound energy analyzes has been done in the Risifrutti production because of the lack of energy meters for steam, electricity and compressed air in the production lines. / Denna rapport är resultatet av ett examensarbete utfört på Risifruttiproduktionen hos företaget Procordia Food AB. Examensarbetet är på D-nivå och är det slutgiltiga arbetet för att författaren ska få en Civilingenjörsexamen inom Innovativ produktion vid Mälardalens Högskola. Examensarbetet omfattar 30 högskolepoäng och har pågått i 18 veckor.   Examensarbetet är i huvudsak en forskning av huruvida det är möjligt att utföra en Miljövärdeflödesanalys på en livsmedelsprocessindustri samt en utvärdering av om Miljövärdeflödesanalys och Green Performance Map verktygen är användbara i denna typ av industri. En bidel till denna forskning är att med hjälp av resultaten från Miljövärdeflödesanalysen ge Procordia Food AB information om vad som bör förbättras i Risifruttiproduktionen.   Författaren har haft det svårt att samla in vissa kvantitativa data till Miljövärdeflödesanalysen, främst beträffande energiåtgång i delprocesserna, men har ändå med hjälp av en Värdeflödesanalys och andra Lean verktyg kunnat identifiera och kvantifiera flera slöserier i Risifruttiproduktionen. Rekommendationer till förbättringar baserade på dessa slöserier har givits till företaget.   I forskningsanalysen har verktygen Värdeflödesanalys, Miljövärdeflödesanalys samt Green Performance Map användbarhet i en livsmedelsprocessindustri analyserats. Författaren har funnit att Värdeflödesanalys är ett användbart verktyg då slöserier och ojämnheter i produktionstakt har kunnat identifieras. Miljövärdeflödesanalys och Green Performance Map verktygen är också bra verktyg när ett företag vill analysera sin miljöbelastning för att sedan investera i miljöförbättringar. Dock har inga djupare energianalyser kunnat göras i Risifruttiproduktionen eftersom energimätare för el, ånga och tryckluft saknades i produktionen.

This study explored the theoretical aspects of Lean Manufacturing principles and identified the practical implementations for a gold processing plant. The success rate of Lean implementations is currently as low as 5% and can be attributed to the failure of management to address the effect of implemented changes on the employees. With this risk in mind, the study included a measurement of the worker perception towards change and organisational climate. The impact of Lean Manufacturing principles was thus quantified by means of practical projects, including an empirical study of how open employees are towards change implementation. The plant process was described and the flow of value was mapped in a Value Stream Map (VSM). The applied principles resulted in three proposed improvement projects with the potential of reducing operating cost, generating additional revenue and eliminating waste. The proposals included reducing lead times through the plant for the two feed sources, namely reef and waste material by 4% and 51% respectively; improved recovery of fine carbon as a by-product of the treatment circuit; and lastly, reducing the lead time for conducted elusions by improving the “flow” of solution throughout the batch process. The quantified financial benefits of the improvements were an estimated additional revenue of R180,000 per month and a further cost saving of R4,000 per month. This study explained that multiple spin-off benefits are realized when improvements are based on Lean Manufacturing principles. Some additional benefits were listed but not quantified in this study. It is important to notice that these specific identified improvements did not require additional capital expenditure, nor long lead times to be implemented. Requirements included an open mind towards change management, time and effort. A survey was conducted to measure the employees’ readiness for change management and the stability of the organisational climate. In the South African mining context, there are external factors impacting on operations of which labor, unions and worker productivity are among the foremost aspects of current concern. This served as motivation for the survey to test employee readiness for Lean Manufacturing changes to be implemented. The statistical internal consistency of the questionnaire, as expressed by the Cronbach alpha coefficients, was acceptable at 0.773 and 0.759 for the change management and organisational climate factors respectively. The p-values and effect sizes were determined within the T-test and ANOVA tests. The group consisting of different years’ experience yielded the most statistical differences in the way that the organisational climate section was completed. The indication was that highly experienced employees answered the questionnaire significantly different than the other groups. The average scoring for the section was above the average and therefore was not considered to be a significant risk to implementation. The group is considered ready for change implementation and the plant should proceed to implement the identified Lean projects. The success and sustainability of the projects can encourage additional improvements. The recommendation is to revisit the future VSM after completion of the projects to identify the next level of improvements for implementation. / MBA, North-West University, Potchefstroom Campus, 2015

This study explored the theoretical aspects of Lean Manufacturing principles and identified the practical implementations for a gold processing plant. The success rate of Lean implementations is currently as low as 5% and can be attributed to the failure of management to address the effect of implemented changes on the employees. With this risk in mind, the study included a measurement of the worker perception towards change and organisational climate. The impact of Lean Manufacturing principles was thus quantified by means of practical projects, including an empirical study of how open employees are towards change implementation. The plant process was described and the flow of value was mapped in a Value Stream Map (VSM). The applied principles resulted in three proposed improvement projects with the potential of reducing operating cost, generating additional revenue and eliminating waste. The proposals included reducing lead times through the plant for the two feed sources, namely reef and waste material by 4% and 51% respectively; improved recovery of fine carbon as a by-product of the treatment circuit; and lastly, reducing the lead time for conducted elusions by improving the “flow” of solution throughout the batch process. The quantified financial benefits of the improvements were an estimated additional revenue of R180,000 per month and a further cost saving of R4,000 per month. This study explained that multiple spin-off benefits are realized when improvements are based on Lean Manufacturing principles. Some additional benefits were listed but not quantified in this study. It is important to notice that these specific identified improvements did not require additional capital expenditure, nor long lead times to be implemented. Requirements included an open mind towards change management, time and effort. A survey was conducted to measure the employees’ readiness for change management and the stability of the organisational climate. In the South African mining context, there are external factors impacting on operations of which labor, unions and worker productivity are among the foremost aspects of current concern. This served as motivation for the survey to test employee readiness for Lean Manufacturing changes to be implemented. The statistical internal consistency of the questionnaire, as expressed by the Cronbach alpha coefficients, was acceptable at 0.773 and 0.759 for the change management and organisational climate factors respectively. The p-values and effect sizes were determined within the T-test and ANOVA tests. The group consisting of different years’ experience yielded the most statistical differences in the way that the organisational climate section was completed. The indication was that highly experienced employees answered the questionnaire significantly different than the other groups. The average scoring for the section was above the average and therefore was not considered to be a significant risk to implementation. The group is considered ready for change implementation and the plant should proceed to implement the identified Lean projects. The success and sustainability of the projects can encourage additional improvements. The recommendation is to revisit the future VSM after completion of the projects to identify the next level of improvements for implementation. / MBA, North-West University, Potchefstroom Campus, 2015

O setor da construção civil é conhecido pela grande incidência de perdas em seus processos, o que tem levado ao crescente uso de práticas baseadas nos sistemas de produção enxuta. Este trabalho apresenta a avaliação da estabilidade e capacidade dos processos, bem como o uso de práticas enxutas em uma obra de pavimentação viária. Inicialmente, a avaliação da estabilidade e capacidade foi realizada por meio do mapeamento do fluxo de valor do estado atual e do desenvolvimento e coleta de indicadores associados aos 4M (Material, Mão-deobra, Máquina e Método). Os resultados indicaram que todos os cinco indicadores avaliados foram estáveis, porém apenas um indicador demonstrou capacidade de atender os parâmetros do cliente. Com base nessa avaliação, foram adotadas ações para redução de perdas e melhora da estabilidade e capacidade dos processos, por meio do uso de práticas enxutas, aplicadas em uma segunda obra com características similares à anterior. As práticas usadas foram: i) Mudança e melhoria de alguns processos construtivos; ii) implantação de ferramenta 5S no canteiro de obras; iii) criação e implantação de dispositivos poka-yokes, iv) aplicação de dispositivo visual de comunicação do tipo andon; v) planejamento de entrega de materiais just-in-time. Nessa segunda obra, os indicadores se mantiveram estáveis, mas foi percebida uma melhora quanto à capacidade destes indicadores em atender os parâmetros exigidos. Apenas o indicador de mão-de-obra turn over não foi capaz de atender a meta definida pela empresa. / The Building Sector is known for high incidence of wastes in its process. This characteristic has been motivating the operators to use some practices based on Lean Production Systems. This paper presents an evaluation of the stability and capacity of Lean Construction concepts in a road construction work. The evaluation of the stability and capacity was realized mapping the current state value stream and the collection of indicators associated with the 4M (Material Hand labor, Machine and Method) The results indicated that all seven indicators measured were stable, but only an indicator of the seven evaluated was considered capable. Based on this evaluation, actions were taken to improve the stability and capacity through the use of lean practices, applied in a second work with similar characteristics to the previous. The practices used were: i) improving / changing some construction processes, ii) 5S tool deployment on construction of works iii) creation and implementation of poka-yokes devices, iv) application of visual tool of andon type communication, v) delivery planning materials within the just-in-time concept. In this second work the indicators remained stable, but a great improvement was perceived, related to the ability of the indicators to meet the required parameters. Only the hand labor turnover indicator was not able to meet the target set by the company.

O setor da construção civil é conhecido pela grande incidência de perdas em seus processos, o que tem levado ao crescente uso de práticas baseadas nos sistemas de produção enxuta. Este trabalho apresenta a avaliação da estabilidade e capacidade dos processos, bem como o uso de práticas enxutas em uma obra de pavimentação viária. Inicialmente, a avaliação da estabilidade e capacidade foi realizada por meio do mapeamento do fluxo de valor do estado atual e do desenvolvimento e coleta de indicadores associados aos 4M (Material, Mão-deobra, Máquina e Método). Os resultados indicaram que todos os cinco indicadores avaliados foram estáveis, porém apenas um indicador demonstrou capacidade de atender os parâmetros do cliente. Com base nessa avaliação, foram adotadas ações para redução de perdas e melhora da estabilidade e capacidade dos processos, por meio do uso de práticas enxutas, aplicadas em uma segunda obra com características similares à anterior. As práticas usadas foram: i) Mudança e melhoria de alguns processos construtivos; ii) implantação de ferramenta 5S no canteiro de obras; iii) criação e implantação de dispositivos poka-yokes, iv) aplicação de dispositivo visual de comunicação do tipo andon; v) planejamento de entrega de materiais just-in-time. Nessa segunda obra, os indicadores se mantiveram estáveis, mas foi percebida uma melhora quanto à capacidade destes indicadores em atender os parâmetros exigidos. Apenas o indicador de mão-de-obra turn over não foi capaz de atender a meta definida pela empresa. / The Building Sector is known for high incidence of wastes in its process. This characteristic has been motivating the operators to use some practices based on Lean Production Systems. This paper presents an evaluation of the stability and capacity of Lean Construction concepts in a road construction work. The evaluation of the stability and capacity was realized mapping the current state value stream and the collection of indicators associated with the 4M (Material Hand labor, Machine and Method) The results indicated that all seven indicators measured were stable, but only an indicator of the seven evaluated was considered capable. Based on this evaluation, actions were taken to improve the stability and capacity through the use of lean practices, applied in a second work with similar characteristics to the previous. The practices used were: i) improving / changing some construction processes, ii) 5S tool deployment on construction of works iii) creation and implementation of poka-yokes devices, iv) application of visual tool of andon type communication, v) delivery planning materials within the just-in-time concept. In this second work the indicators remained stable, but a great improvement was perceived, related to the ability of the indicators to meet the required parameters. Only the hand labor turnover indicator was not able to meet the target set by the company.

O setor da construção civil é conhecido pela grande incidência de perdas em seus processos, o que tem levado ao crescente uso de práticas baseadas nos sistemas de produção enxuta. Este trabalho apresenta a avaliação da estabilidade e capacidade dos processos, bem como o uso de práticas enxutas em uma obra de pavimentação viária. Inicialmente, a avaliação da estabilidade e capacidade foi realizada por meio do mapeamento do fluxo de valor do estado atual e do desenvolvimento e coleta de indicadores associados aos 4M (Material, Mão-deobra, Máquina e Método). Os resultados indicaram que todos os cinco indicadores avaliados foram estáveis, porém apenas um indicador demonstrou capacidade de atender os parâmetros do cliente. Com base nessa avaliação, foram adotadas ações para redução de perdas e melhora da estabilidade e capacidade dos processos, por meio do uso de práticas enxutas, aplicadas em uma segunda obra com características similares à anterior. As práticas usadas foram: i) Mudança e melhoria de alguns processos construtivos; ii) implantação de ferramenta 5S no canteiro de obras; iii) criação e implantação de dispositivos poka-yokes, iv) aplicação de dispositivo visual de comunicação do tipo andon; v) planejamento de entrega de materiais just-in-time. Nessa segunda obra, os indicadores se mantiveram estáveis, mas foi percebida uma melhora quanto à capacidade destes indicadores em atender os parâmetros exigidos. Apenas o indicador de mão-de-obra turn over não foi capaz de atender a meta definida pela empresa. / The Building Sector is known for high incidence of wastes in its process. This characteristic has been motivating the operators to use some practices based on Lean Production Systems. This paper presents an evaluation of the stability and capacity of Lean Construction concepts in a road construction work. The evaluation of the stability and capacity was realized mapping the current state value stream and the collection of indicators associated with the 4M (Material Hand labor, Machine and Method) The results indicated that all seven indicators measured were stable, but only an indicator of the seven evaluated was considered capable. Based on this evaluation, actions were taken to improve the stability and capacity through the use of lean practices, applied in a second work with similar characteristics to the previous. The practices used were: i) improving / changing some construction processes, ii) 5S tool deployment on construction of works iii) creation and implementation of poka-yokes devices, iv) application of visual tool of andon type communication, v) delivery planning materials within the just-in-time concept. In this second work the indicators remained stable, but a great improvement was perceived, related to the ability of the indicators to meet the required parameters. Only the hand labor turnover indicator was not able to meet the target set by the company.

This thesis focuses on the management of a selected part of the production process in IMI Precision Engineering and aims to present a proposal for the introduction of a new approach to managing the production task of the given production process part using the Kanban model. The subject of the analysis is the inventory of the given production process part, which are analysed based on ABC / XYZ analysis, the conclusions of which, presented in the design part of the thesis, serve as basis for the creation of a proposal for the introduction of Kanban.

Dagens parallella ökning av konsumtion och hållbarhetstänk ställer höga krav på företag. Digitaliseringen och den tekniska progressionen utmanar företag än mer att arbeta mot ständig förbättring för att bibehålla sin konkurrenskraft och är en aspekt som studien lyfter. En av de väsentligaste aktiviteterna att reformera för en transportdistributör inom tillväxtfasen är dess planering och i denna studie läggs vikten således på rutteffektivisering utifrån både kostnads-och miljöaspekter. För att utforma en gynnsam ruttplanering är en av de viktigaste aspekterna informationsflödet. Det finns en tydlig koppling att företag som har ett ineffektivt informationsflöde har svårigheter med att ta fram en ruttplanering som är effektiv. Studien har sitt fokus på mindre företag som befinner sig i tillväxtfasen och hur dessa fördelaktigt kan effektivisera sin ruttplanering och informationsflöde för att bibehålla sin konkurrenskraftighet. Utifrån det teoretiska ramverket, intervjuer och tilldelad data identifieras brister inom informationsflödet och ruttplaneringen. Teorier om omvänd logistik, ruttplanering, värdeflödesanalys och informationssystem med fokus på kommunikation kommer appliceras och användas. Det ska dessutom påvisas varför en bra och välutvecklad ruttplanering är mer gynnsam för ett företag. Via en kartläggning har dessa brister undersökts och reformeringsförslag på informationsflödet har framställts. Dessutom har, via en jämförelse av ruttplanering mellan ett stort mer erfaret företag och ett litet företag med mindre erfarenhet, fördelar och tankesätt kring utförandet av en ruttplanering framtagits. Det visar sig att ett noggrant och grundligt genomtänkt ruttplanering och information och kommunikations-system anpassat efter organisationens behov och prioriteringar skapar konkurrenskraftighet, till skillnad från att använda penna och papper metoden. Vetenskapligt framtagna manuella ruttplaneringsmetoder så som fasta slingor och svepmetoden appliceras fördelaktigt på ett företag i tillväxtfasen. Det genererar samtidigt i en hög kundtillfredsställelse och lönsamhet samtidigt som det ökar miljömedvetenheten hos små företag i tillväxtfasen. Utöver detta skapas en trygghet för den anställde och kontroll över företagets resurser och kapaciteter fås. Problem som är förekommande inom informationsflödet är bland annat ej standardiserad information i körscheman men med hjälp av rutiner, standarder och ett nuläge att utgå ifrån kan ett förbättringsarbete påbörjas och styras i rätt riktning. Studien påvisar att detta är av stor vikt även inom ruttplanering. / Today's parallel increase in consumption and sustainability thinking places high demands on companies. Digitization and technological progression challenge companies even more to work towards continuous improvement in order to maintain their competitiveness and is an aspect that the study highlights. One of the most important activities to reform for a transport distributor within the growth phase is its planning, and in this study the emphasis is thus on route efficiency based on both cost and environmental aspects. In order to design a profitable route planning, one of the most important aspects is the information flow. There is a clear link that companies that have an inefficient information flow have difficulties in developing a route planning that is efficient. The study focuses on smaller companies that are in the growth phase and how these can advantageously streamline their route planning and information flow to maintain their competitiveness. Based on the theoretical framework, interviews and assigned data, shortcomings in the information flow and route planning are identified. Theories of reverse logistics, route planning, value stream map analysis and information systems with a focus on communication will be applied and used. It also demonstrates why a good and well-developed route planning is more favorable for a company. Through a survey, these shortcomings have been investigated and reform proposals for the information flow have been made. In addition, through a comparison of route planning between a large, more experienced company, and a small company with less experience, advantages, and ways of thinking about the execution of a route planning have been developed. It turns out that a carefully and thoroughly thought-out route planning and information and communication system adapted to the organization's needs and priorities creates competitiveness, as opposed to using the pen and paper method. Scientifically developed manual route planning methods such as fixed loops and the sweep method are advantageously applied to a company in the growth phase. At the same time, it generates a high level of customer satisfaction and profitability while increasing the environmental awareness of small companies in the growth phase. In addition to this, security is created for the employee and control over the company's resources and capacities is gained. Problems that occur in the information flow include non-standardized information in driving schedules, but with the help of routines, standards, and a current situation to compare with, improvement work can be started and steered in the right direction. The study shows that it is also of great importance when it comes to route planning.