Mejoramiento de procesos de manufactura utilizando Kanban

Este artículo presenta la aplicación de la metodología Kanban y el análisis del efecto que puede generar en una empresa de fabricación de transformadores de distribución. Mediante la aplicación de la metodología propuesta es posible mejorar la programación de la producción, con el objetivo de reducir la cantidad de producto en proceso que no es utilizado, de forma que se reduzca el inventario. Para analizar el efecto de aplicar la metodología Kanban en la empresa, se utilizo la técnica de simulación, para lo cual se modelizan el proceso actual y el propuesto con las reglas de dicha metodología. A partir de los resultados que arrojan dichas modelizaciones, se observa que existe un mejoramiento en las líneas de producción cuando se utiliza la metodología Kanban.

A systematic approach for selecting lean strategies and assessing leanness in manufacturing organizations

Lean strategies have been developed to eliminate or reduce manufacturing waste and thus improve operational efficiency in manufacturing processes. However, implementing lean strategies requires a large amount of resources and, in practice, manufacturers encounter difficulties in selecting appropriate lean strategies within their resource constraints. There is currently no systematic methodology available for selecting appropriate lean strategies within a manufacturer's resource constraints. In the lean transformation process, it is also critical to measure the current and desired leanness levels in order to clearly evaluate lean implementation efforts. Despite the fact that many lean strategies are utilized to reduce or eliminate manufacturing waste, little effort has been directed towards properly assessing the leanness of manufacturing organizations. In practice, a single or specific group of metrics (either qualitative or quantitative) will only partially measure the overall leanness. Existing leanness assessment methodologies do not offer a comprehensive evaluation method, integrating both quantitative and qualitative lean measures into a single quantitative value for measuring the overall leanness of an organization. This research aims to develop mathematical models and a systematic methodology for selecting appropriate lean strategies and evaluating the leanness levels in manufacturing organizations. Mathematical models were formulated and a methodology was developed for selecting appropriate lean strategies within manufacturers' limited amount of available resources to reduce their identified wastes. A leanness assessment model was developed by using the fuzzy concept to assess the leanness level and to recommend an optimum leanness value for a manufacturing organization. In the proposed leanness assessment model, both quantitative and qualitative input factors have been taken into account. Based on program developed in MATLAB and C#, a decision support tool (DST) was developed for decision makers to select lean strategies and evaluate the leanness value based on the proposed models and methodology hence sustain the lean implementation efforts. A case study was conducted to demonstrate the effectiveness of these proposed models and methodology. Case study results suggested that out of 10 wastes identified, the case organization (ABC Limited) is able to improve a maximum of six wastes from the selected workstation within their resource limitations. The selected wastes are: unnecessary motion, setup time, unnecessary transportation, inappropriate processing, work in process and raw material inventory and suggested lean strategies are: 5S, Just-In-Time, Kanban System, the Visual Management System (VMS), Cellular Manufacturing, Standard Work Process using method-time measurement (MTM), and Single Minute Exchange of Die (SMED). From the suggested lean strategies, the impact of 5S was demonstrated by measuring the leanness level of two different situations in ABC. After that, MTM was suggested as a standard work process for further improvement of the current leanness value. The initial status of the organization showed a leanness value of 0.12. By applying 5S, the leanness level significantly improved to reach 0.19 and the simulation of MTM as a standard work method shows the leanness value could be improved to 0.31. The optimum leanness value of ABC was calculated to be 0.64. These leanness values provided a quantitative indication of the impacts of improvement initiatives in terms of the overall leanness level to the case organization. Sensitivity analsysis and a t-test were also performed to validate the model proposed. This research advances the current knowledge base by developing mathematical models and methodologies to overcome lean strategy selection and leanness assessment problems. By selecting appropriate lean strategies, a manufacturer can better prioritize implementation efforts and resources to maximize the benefits of implementing lean strategies in their organization. The leanness index is used to evaluate an organization's current (before lean implementation) leanness state against the state after lean implementation and to establish benchmarking (the optimum leanness state). Hence, this research provides a continuous improvement tool for a lean manufacturing organization.

Simulated systems optimization through response surface techniques [Optimización de sistemas simulados a través de técnicas de superficie de respuesta]

The purpose of this article is to show the applicability and benefits of the techniques of design of experiments as an optimization tool for discrete simulation models. The simulated systems are computational representations of real-life systems; its characteristics include a constant evolution that follows the occurrence of discrete events along the time. In this study, a production system, designed with the business philosophy JIT (Just in Time) is used, which seeks to achieve excellence in organizations through waste reduction in all the operational aspects. The most typical tool of JIT systems is the KANBAN production control that seeks to synchronize demand with flow of materials, minimize work in process, and define production metrics. Using experimental design techniques for stochastic optimization, the impact of the operational factors on the efficiency of the KANBAN / CONWIP simulation model is analyzed. The results show the effectiveness of the integration of experimental design techniques and discrete simulation models in the calculation of the operational parameters. Furthermore, the reliability of the methodologies found was improved with a new statistical consideration.

Business process performance mining with staged process flows

Existing process mining techniques provide summary views of the overall process performance over a period of time, allowing analysts to identify bottlenecks and associated performance issues. However, these tools are not de- signed to help analysts understand how bottlenecks form and dissolve over time nor how the formation and dissolution of bottlenecks – and associated fluctua- tions in demand and capacity – affect the overall process performance. This paper presents an approach to analyze the evolution of process performance via a notion of Staged Process Flow (SPF). An SPF abstracts a business process as a series of queues corresponding to stages. The paper defines a number of stage character- istics and visualizations that collectively allow process performance evolution to be analyzed from multiple perspectives. The approach has been implemented in the ProM process mining framework. The paper demonstrates the advantages of the SPF approach over state-of-the-art process performance mining tools using two real-life event logs publicly available.

Lean Software Management: BBC Worldwide Case Study

This case study examines how the lean ideas behind the Toyota production system can be applied to software project management. It is a detailed investigation of the performance of a nine-person software development team employed by BBC Worldwide based in London. The data collected in 2009 involved direct observations of the development team, the kanban boards, the daily stand-up meetings, semistructured interviews with a wide variety of staff, and statistical analysis. The evidence shows that over the 12-month period, lead time to deliver software improved by 37%, consistency of delivery rose by 47%, and defects reported by customers fell 24%. The significance of this work is showing that the use of lean methods including visual management, team-based problem solving, smaller batch sizes, and statistical process control can improve software development. It also summarizes key differences between agile and lean approaches to software development. The conclusion is that the performance of the software development team was improved by adopting a lean approach. The faster delivery with a focus on creating the highest value to the customer also reduced both technical and market risks. The drawbacks are that it may not fit well with existing corporate standards.

Development of a platform for lean manufacturing simulation games

More than ever, the economic globalization is creating the need to increase business competitiveness. Lean manufacturing is a management philosophy oriented to the elimination of activities that do not create any type of value and are thus considered a waste. One of the main differences from other management philosophies is the shop-floor focus and the operators' involvement. Therefore, the training of all organization levels is crucial for the success of lean manufacturing. Universities should also participate actively in this process by developing students' lean management skills and promoting a better and faster integration of students into their future organizations. This paper proposes a single realistic manufacturing platform, involving production and assembly operations, to learn by playing many of the lean tools such as VSM, 5S, SMED, poke-yoke, line balance, TPM, Mizusumashi, plant layout, and JIT/kanban. This simulation game was built in tight cooperation with experienced lean companies under the international program “Lean Learning Academy,”http://www.leanlearningacademy.eu/ and its main aim is to make bachelor and master courses in applied sciences more attractive by integrating classic lectures with a simulated production environment that could result in more motivated students and higher study yields. The simulation game results show that our approach is efficient in providing a realistic platform for the effective learning of lean principles, tools, and mindset, which can be easily included in course classes of less than two hours.

Implementação da filosofia Lean na gestão dos serviços de saúde: o caso português

Dissertação apresentada ao Instituto Politécnico do Porto para obtenção do Grau de Mestre em Gestão das Organizações, Ramo de Gestão de Empresas. Orientada por Prof. Dra. Maria Rosário Moreira e Prof. Dr. Paulo Sousa

Gestão de operações de um armazém

i Gestão de Operações de um armazém Patrícia Raquel Freitas Gomes Relatório de estágio apresentado ao Instituto Superior de Contabilidade e Administração do Porto para obtenção de Grau de Mestre em Logística Orientado por: Prof. Doutora Maria Teresa Ribeiro Pereira Coorientado por: Eng.º César Emanuel Marinho Carvalho Teixeira

Teoría de las restricciones (TOC): Modelo de Gestión Gerencial para el Crecimiento Productivo de las Pymes en Colombia. Caso aplicado a CIDMA S.A.S.

En los últimos años, un panorama turbulento, dinámico y caótico ha caracterizado la industria de las confecciones en Colombia. Como consecuencia, la incertidumbre y la competencia han dificultado la toma de decisiones que le permitan a las pymes crear estrategias oportunas para alcanzar sus metas, disminuir los riesgos y lograr subsistir en el entorno en el que se desenvuelven a través del mejoramiento del sistema productivo y financiero. La academia de la administración ha buscado herramientas teóricas y prácticas que le permitan a las empresas afrontar la complejidad actual, y por ello, el modelo de gestión gerencial de las Teorías de las Restricciones – TOC- ha tenido una gran aceptación, no solo en organizaciones grandes, sino que ha desarrollado un mayor número de seguidores en las pymes. El presente artículo presenta una revisión teórica y posteriormente el caso práctico de CIDMA S.A.S., enfocándose en cómo esta herramienta permite identificar los problemas raíz de la organización para desarrollar estrategias de mejora continua que se reflejan en su sistema financiero.

Simulating the change from a push to pull production system

This paper will document the initial discrete-event simulation performed to study a proposed change from a push to a pull system in an existing manufacturing company. The system is characterised by five machine lines with intermediate buffers, and five major part groupings. A simulation model has been developed to mimic the flow of kanban cards in the physical system, by using a series of requests that propagate back through the facility, which the machines must respond to. The customer
demand therefore controls the level of activity in the plant. The results of the initial modelling steps will be presented in this paper, especially the impact of kanban lot size and demand variability on the output and stability of the production system, from which a set of future work is proposed.

Application of co-operative agents in handling fluctuations in a pull production system

This paper presents the general details of the structure and strategy of a multi-agent system that is being developed to improve the performance of pull (kanban) production control to handle large fluctuations in product demand. Employing a set of generic, heterarchial agents each controlling a single product and co-operating together to ensure that all components, regardless of demand fluctuation, are manufactured on time as per basic kanban principles. Preliminary results indicate that the basic kanban model does not cater for large demand fluctuations and the application of this multi-agent strategy may be beneficial to improving the overall system performance and increase the likelihood that all products will be manufactured on time.

Bringing Japanese manufacturing systems to America: the feasibility of implementing just-in-time production in the United States

This paper addresses the feasibility of implementing Japanese manufacturing systems in the United States. The recent success of Japanese transplant companies suggests that Just-In-Time (JIT) production is possible within America's industrial environment. Once American workers receive proper training, they have little difficulty participating in rapid setup procedures and utilizing the kanban system. Japanese transplants are gradually developing Japanese-style relationships with their American supplier companies by initiating long-term, mutually beneficial agreements. They are also finding ways to cope with America's problem of distance, which is steadily decreasing as an obstacle to JIT delivery. American companies, however, encounter Significant problems in trying to convert traditionally organized, factories to the JIT system. This paper demonstrates that it is both feasible and beneficial for American manufacturers to implement JIT production techniques. Many of the difficulties manufacturers experience center around a general lack of information about JIT. Once a company realizes its potential for setup-time reduction, a prerequisite for the JIT system, workers and managers can work together to create a new process for handling equipment changeover. Significant results are possible with minimal investment. Also, supervisors often do not realize that the JIT method of ordering goods from suppliers is compatible with current systems. This "kanban system" not only enhances current systems but also reduces the amount of paperwork and scheduling involved. When arranging JlT delivery of supplier goods, American manufacturers tend to overlook important aspects of JIT supplier management. However, by making long-tenn commitments, initiating the open exchange of information, assisting suppliers in reaching new standards of performance, increasing the level of conununication, and relying more on suppliers' engineering capabilities, even American manufacturers can develop Japanese-style supplier relationships that enhance the effectiveness of the system.