Suorituskyvyn johtamisjärjestelmän jalkauttamisen ja tehokkaan käyttämisen edistäminen bioenergia- ja lämpöliiketoimialalla

Tämän tutkimuksen tavoitteena on selvittää suorituskyvyn johtamisjärjestelmän jalkauttamisen, tehokkaan käyttämisen ja jatkuvan parantamisen kulttuurin luomisen edistäviä tekijöitä bioenergia- ja lämpöliiketoimialalla. Tämä tutkimus tukee kohdeorganisaation suorituskyvyn johtamisjärjestelmän implementointiprosessia. Tutkimuksen mukaan suorituskyvyn johtamisjärjestelmän jalkauttamista tukee kolme tärkeää tekijää: johdon ja henkilöstön sitoutuminen, mittariston hyödyllisyyden näkeminen ja mittariston rakenne ja sisältö. Johdon ja henkilöstön sitoutumista sekä mittariston hyödyllisyyden näkemistä edistävät oikeanlainen viestintä, mittariston ymmärtäminen ja liiketoimintaa tukevat mittarit. Mittareiden käyttöönottoa edistävät ymmärrettävät ja luotettavat mittarit sekä kannustimet. Tutkimuksen mukaan suorituskykymittariston tehokasta käyttämistä tukevat mittareiden ajantasaisuus ja mittaustiedon hyödyntäminen liiketoiminnassa. Mittariston tehokasta käyttämistä edistävät mittariston muutosherkkyys, käyttäjäläheinen kehittäminen ja mittareiden liittäminen palkitsemiseen. Jatkuvan parantamisen kulttuurin luomista edistävät mittaristoon ja organisaatioon liittyvät tekijät mm. organisaatiokulttuuri ja johtamistyyli sekä mittariston muutosherkkyys.

Tuotantoympäristön jatkuva parantaminen

Tutkimuksen tavoitteena oli luoda kohdeyritykseen toimintamalli, jonka avulla saadaan osallistettua työntekijät, tiiminvetäjät ja työnjohto tuotannon jatkuvaan parantamiseen sekä parannettua tuotannon takaisinkytkentää tiimitasolla. Tutkimus rajattiin pilottitiimiin sekä tiimissä olevien työpisteiden kautta reititettyihin tuotteisiin. Ennen tutkimuksen aloitusta yrityksellä oli jo olemassa sähköinen aloitejärjestelmä, mutta sen käyttö oli organisaation uudelleen järjestelyjen myötä vähentynyt. Tutkimuksen teoriaosassa tutustuttiin jatkuvan parantamisen kulttuuriin ja työkaluihin. Lisäksi tutustuttiin laadunhallinnan sisältöön, käsitteistöön ja laadunvalvontatyökaluihin sekä tuotannon mittareihin. Teorian pohjalta tutkimuksessa luotiin jatkuvan parantamisen toimintamalli, joka tunnistaa ja eliminoi prosessissa olevaa hukkaa osallistamalla pilottitiimin työntekijöitä hukkakorttien avulla. Lisäksi tutkimuksessa luotiin toimintamalli tuotannon kehitysideoiden raportointiin ja käsittelyyn. Tuotannon takaisinkytkentää kehitettiin luomalla pilottitiimiin tuloskortti sekä perustamalla yritykseen päiväkatsauskäytäntö. Tutkimuksessa suoritettiin myös toimihenkilötason kehitysprojekteja käyttäen apuna teoriassa esiteltyjä malleja ja työkaluja. Tuloksena saatiin toimintamalli, joka tuottaa työntekijämäärään suhteutettuna enemmän kehitysideoita sekä käsittelee ne tehokkaammin kuin sähköinen aloitejärjestelmä. Hukkakorteilla toteutetun hukan raportoinnin kautta tunnistettiin ja raportoitiin seitsemän viikon tarkasteluajanjakson aikana yhteensä 23,6 tuntia hukka-aikaa. Tiimin tuloskortin avulla tiimin työntekijät pystyivät viikkotasolla seuraamaan oman tiiminsä suorituskykyä tavoitearvoihin verrattuna. Tämä näkyi muun muassa tiimin suoritustason nousuna. Kehitysprojektien avulla saatiin parannettua pilottitiimin toiminnan ja tuotteiden laatua. Päiväkatsauskäytännön avulla saatiin osallistettua tiiminvetäjät ongelmaratkaisuun sekä tuotannon suorituskyvyn varmistamiseen.

Defining Sales and Operations Planning Process in an Environmental Management Company

Sales and operations research publications have increased significantly in the last decades. The concept of sales and operations planning (S&OP) has gained increased recognition and has been put forward as the area within Supply Chain Management (SCM). Development of S&OP is based on the need for determining future actions, both for sales and operations, since off-shoring, outsourcing, complex supply chains and extended lead times make challenges for responding to changes in the marketplace when they occur. Order intake of the case company has grown rapidly during the last years. Along with the growth, new challenges considering data management and information flow have arisen due to increasing customer orders. To manage these challenges, case company has implemented S&OP process, though initial process is in early stage and due to this, the process is not managing the increased customer orders adequately. Thesis objective is to explore extensively the S&OP process content of the case company and give further recommendations. Objectives are categorized into six different groups, to clarify the purpose of this thesis. Qualitative research methods used are active participant observation, qualitative interviews, enquiry, education, and a workshop. It is notable that demand planning was felt as cumbersome, so it is typically the biggest challenge in S&OP process. More proactive the sales forecasting can be, more expanded the time horizon of operational planning will turn out. S&OP process is 60 percent change management, 30 percent process development and 10 percent technology. The change management and continuous improvement can sometimes be arduous and set as secondary. It is important that different people are required to improve the process and the process is constantly evaluated. As well as, process governance is substantially in a central role and it has to be managed consciously. Generally, S&OP process was seen important and all the stakeholders were committed to the process. Particular sections were experienced more important than others, depending on the stakeholders’ point of views. Recommendations to objective groups are evaluated by the achievable benefit and resource requirement. The urgent and easily implemented improvement recommendations should be executed firstly. Next steps are to develop more coherent process structure and refine cost awareness. Afterwards demand planning, supply planning, and reporting should be developed more profoundly. For last, information technology system should be implemented to support the process phases.

Integration of marketing research data in new product development. Case study: Food industry company

The aim of this master’s thesis is to provide a real life example of how marketing research data is used by different functions in the NPD process. In order to achieve this goal, a case study in a company was implemented where gathering, analysis, distribution and synthesis of marketing research data in NPD were studied. The main research question was formulated as follows: How is marketing research data integrated and used by different company functions in the NPD process? The theory part of the master’s thesis was focused on the discussion of the marketing function role in NPD, use of marketing research particularly in the food industry, as well as issues related to the marketing/R&D interface during the NPD process. The empirical part of the master’s thesis was based on qualitative explanatory case study research. Individual in-depth interviews with company representatives, company documents and online research were used for data collection and analyzed through triangulation method. The empirical findings advocate that the most important marketing data sources at the concept generation stage of NPD are: global trends monitoring, retailing audit and consumers insights. These data sets are crucial for establishing the potential of the product on the market and defining the desired features for the new product to be developed. The findings also suggest the example of successful crossfunctional communication during the NPD process with formal and informal communication patterns. General managerial recommendations are given on the integration in NPD of a strategy, process, continuous improvement, and motivated cross-functional product development teams.

Leanin soveltaminen haavanhoitotuotteiden valmistuksen läpimenoaikojen lyhentämiseksi

Mölnlycke Health Care valmistaa kertakäyttöisiä leikkaussali- ja haavanhoitotuotteita. Yritys on saavuttanut arvostetun aseman markkinoilla ja pitääkseen asemansa sen tulee koko ajan kehittää toimintaansa. Keväällä 2016 yritys aloitti leanin implementoinnin, minkä vuoksi nykytilanteen kartoittaminen ja sen pohjalta tuotannon kehittäminen tuli ajankohtaiseksi. Diplomityössä selvitettiin Mölnlycke Health Care Oy:lle sopiva nykytilan kartoitusmenetelmä. Sopivaksi menetelmäksi osoittautui arvovirtakuvaus. Nykytilanteen kartoitus tehtiin yrityksen kannalta tärkeälle tuoteperheelle, joka tässä tapauksessa oli edistyksellinen haavanhoitotuote ja haavasidos Mepilex Border. Nykytilanteen kartoitus antoi tuotteen läpimenoajaksi 100 päivää varaston riitto huomioituna. Tästä ajasta kuitenkin suurin osa oli hukkaa, jota pystytään poistamaan. Nykytilanteesta tehtiin kuva, jonka pohjalta pystyttiin havainnoimaan kehittävät kohteet ja tekemään ehdotukset kohteiden parantamiseksi. Kehitysehdotusten tavoitteena oli tuoda yritystä lähemmäs Lean-filosofiaa ja auttaa pitämään yllä jatkuvan parantamisen kulttuuria.

Activity-based life cycle costing model for cost estimation and monitoring – Case: manned and autonomous dry bulk carrier

Recent developments in automation, robotics and artificial intelligence have given a push to a wider usage of these technologies in recent years, and nowadays, driverless transport systems are already state-of-the-art on certain legs of transportation. This has given a push for the maritime industry to join the advancement. The case organisation, AAWA initiative, is a joint industry-academia research consortium with the objective of developing readiness for the first commercial autonomous solutions, exploiting state-of-the-art autonomous and remote technology. The initiative develops both autonomous and remote operation technology for navigation, machinery, and all on-board operating systems. The aim of this study is to develop a model with which to estimate and forecast the operational costs, and thus enable comparisons between manned and autonomous cargo vessels. The building process of the model is also described and discussed. Furthermore, the model’s aim is to track and identify the critical success factors of the chosen ship design, and to enable monitoring and tracking of the incurred operational costs as the life cycle of the vessel progresses. The study adopts the constructive research approach, as the aim is to develop a construct to meet the needs of a case organisation. Data has been collected through discussions and meeting with consortium members and researchers, as well as through written and internal communications material. The model itself is built using activity-based life cycle costing, which enables both realistic cost estimation and forecasting, as well as the identification of critical success factors due to the process-orientation adopted from activity-based costing and the statistical nature of Monte Carlo simulation techniques. As the model was able to meet the multiple aims set for it, and the case organisation was satisfied with it, it could be argued that activity-based life cycle costing is the method with which to conduct cost estimation and forecasting in the case of autonomous cargo vessels. The model was able to perform the cost analysis and forecasting, as well as to trace the critical success factors. Later on, it also enabled, albeit hypothetically, monitoring and tracking of the incurred costs. By collecting costs this way, it was argued that the activity-based LCC model is able facilitate learning from and continuous improvement of the autonomous vessel. As with the building process of the model, an individual approach was chosen, while still using the implementation and model building steps presented in existing literature. This was due to two factors: the nature of the model and – perhaps even more importantly – the nature of the case organisation. Furthermore, the loosely organised network structure means that knowing the case organisation and its aims is of great importance when conducting a constructive research.

Increasing value add in white collar work using lean methods

The efficient indirect office work brings competitive advantage for companies in a rapidly changing business environment. The direct work methods in factory floors have been developed already for decades, but the office work is an area where the potential to improve the value add has not been studied and utilized systematically so far. The first objective of the thesis work is to find useful method for identifying and managing value add using literature. The usefulness of the method is validated in the case company`s environment. The second objective of the work is to understand what kind of effort is required to create more efficient target setting for the white collar employees. The operative level targets should be linked more tightly to the company strategy. Lean methods are selected as a tool for the improvement, since they are widely used in all kinds of industries and they are already familiar in other functions in the case company. Based on the literature review, suitable improvement methods are selected. The core of the lean is to identify the value add of a customer and eliminate the waste. Also visual control, cross functional work team, flow office and continuous improvement are used. The methods are tested in one production line and the results and feedback indicate that methods are useful in the studied environment.

Improvement of Operational Efficiency effectiveness (OEE) using Six Sigma DMAIC Methodology — Case Bottomer line AD2378

Overall Equipment Effectiveness (OEE) is the key metric of operational excellence. OEE monitors the actual performance of equipment relative to its performance capabilities under optimal manufacturing conditions. It looks at the entire manufacturing environment measuring, in addition to the equipment availability, the production efficiency while the equipment is available to run products, as well as the efficiency loss that results from scrap, rework, and yield losses. The analysis of the OEE provides improvement opportunities for the operation. One of the tools used for OEE improvement is Six Sigma DMAIC methodology which is a set of practices originally developed to improve processes by eliminating defects. It asserts the continuous efforts to reduce variation in process outputs as key to business success, as well as the possibility of measurement, analysis, improvement and control of manufacturing and business processes. In the case of the Bottomer line AD2378 in Papsac Maghreb Casablanca plant, the OEE figures reached 48.65 %, which is below the accepted OEE group performance. This required immediate actions to achieve OEE improvement. This Master thesis focuses on the application of Six Sigma DMAIC methodology in the OEE improvement on the Bottomer Line AD2378 in Papsac Maghreb Casablanca plant. First, the Six Sigma DMAIC and OEE usage in operation measurement will be discussed. Afterwards, the different DMAIC phases will allow the identification of improvement focus, the identification of OEE low performance causes and the design of improvement solutions. These will be implemented to allow further tracking of improvement impact on the plant operations.