Manufatura enxuta voltado para industrias siderúrgicas que utilizam sistemas de produção sob encomenda: um estudo de caso de uma empresa siderúrgica nacional

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

A produção enxuta em um sistema de fabricação contínuo: aplicação da simulação discreta estocástica na indústria de condutores elétricos

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Análise da implementação dos elementos e ferramentas da produção enxuta em canteiros de obras na cidade de Belém do Pará

As empresas do setor da construção civil em Belém, estão buscando formas de melhorar seus processos e métodos construtivos através da implementação dos elementos e ferramentas do sistema de produção enxuta. O objetivo deste trabalho consistiu em avaliar os casos de sucesso e fracasso, através de um estudo exploratório da implementação do sistema de produção enxuta nos canteiros de obras na cidade de Belém do Pará, para identificar quais os elementos e ferramentas desse sistema são mais usadas na construção civil da cidade em questão. Desta forma, realizou-se uma ampla pesquisa bibliográfica sobre o assunto, mostrando a evolução histórica desde a criação da administração científica, destacando os precursores da administração da produção, em seguida, relatando o surgimento do sistema de produção enxuta, assim como suas origens e pilares, destacando seus elementos e ferramentas. A metodologia de pesquisa utilizada foi estudo de caso de caráter exploratório, onde o foco foram os gestores que atuam aplicando a produção enxuta em suas obras. Os dados foram coletados através da aplicação de um questionário com classificação de perguntas, fechadas e de múltipla escolha, composto por vinte questões objetivas, afim de, gerar dados para responder a questão de pesquisa. Após a coleta dos dados, foram geradas tabelas e gráficos para análise dos resultados. Os resultados analisados apontaram os elementos e ferramentas lean mais utilizados, além de apresentar as maiores dificuldades na implementação do sistema de produção enxuta, e em seguida, foi realizado uma correlação entre as dificuldades encontradas com a literatura pertinente. A partir disso, concluiu-se que as empresas não estão totalmente comprometida com o sistema de implementação de melhorias (SPE), de maneira que isto desmotiva os operários e cria resistência a mudanças.

Modelo conceitual de gestão de produção baseado na gestão do conhecimento: um estudo no ambiente operário da indústria automotiva

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Melhoria do processo de reparo por meio da redução de Lead Time em uma empresa de som automotivo

The constant search for improvement and survival of the companies makes essential the utilization of cost reduction strategies and resources optimization. This study had as its objective the utilization of Lean Manufacturing tools for the repair process lead time reduction, in a car audio manufacturer. Performing an action research, the major problems were studied, such as the potential causes and the possible improvement activities, using the DMAIC methodology. An action plan was developed for all involved processes and, as a result, the objective was reached by making a direct impact on the customers’ satisfaction and adding a competitive differential for the company

A aplicação da teoria do lean seis sigma na prestação de serviços no setor agrícola

This thesis aims to analyze the applicability of Lean Six Sigma and DMAIC to improve processes focused on agriculture. We discuss the origins of each system separately, Lean Manufacturing, the Toyota plants in Japan, and Six Sigma, by Motorola in the U.S., and then appears to merge them and can meet their complementarities and synergy between their tools. Finally, we describe a case study focused on the harvesting department, applicable to all types of manuals crops, covering the production of fruits, vegetables and greens. This study shows the ability to reduce costs, increase productivity and elimination of defects that the methodology developed with the fusion of Lean Manufacturing with Six Sigma allows

A obtenção de ganhos produtivos e diminuição dos desperdícios com a implementação de manufatura enxuta em uma indústria metalúrgica

This work was developed with the aim of explaining the real benefits of using the concept of Lean Manufacturing in a Metallurgical Industry. Through this will highlight the strategies and real gains from the use of this methodology and therefore, the tools of Production Engineering that were used in the implementation of Lean Manufacturing, in order to improve processes in various aspects such as reduced handling, standardization of production, reduced time used in machine setup. Practical methods applied for the purpose of reducing waste become apparent. Also highlighted will be the real difficulties encountered in the implementation of Lean Manufacturing

Implementação de produção enxuta em uma empresa de manutenção de equipamentos rotativos

This graduation work presents the implementation of the key concepts of lean thinking in a maintenance workshop of rotating equipment, analyzing all the administrative and workshop processes. The pursuit of quality and client satisfaction at lower costs has generated a lot of competition between organizations, which use the practices of lean manufacturing as tools for processes improvement, aiming to eliminate wastes, being this, the work objective. And, unlike a manufacturing system, where the product goes through certain stages until its conclusion, the workshop does not have a default sequence that is repeated routinely on all machines. Thus, it demonstrates a possibility of application of lean tools in a different way of the common used in the lean manufacturing

Adoption of lean thinking practices at Brazilian auto part companies

The objective of this study is to analyze the adoption of lean thinking practices at Brazilian auto part companies. For such, a survey was conducted at 75 sector companies. The results reveal that among all practices, the “systematic search for continuous improvement" obtained the highest implementation average. In terms of correlation, interdependence was observed among all Lean Manufacturing variables, most especially between LM5 (Kanban) and LM6 (Just-in-Time). This correlation can be explained by the importance of Kanban systems when implementing Just-inTime.

Fatores críticos de sucesso na implementação e gerenciamento do pensamento enxuto: um estudo na manufatura de fitas acrílicas

As a result of the industrial competitiveness increase in recent decades, concern about process improvements has been growing significantly. Lean Thinking principles are being more and more applied in the different sectors of the industry and aim to reduce costs, which can generate satisfactory results for an organization. Besides the application of lean tools on workstations, Lean Thinking seeks cultural change of the employees. Although the concepts of this management philosophy are widely disseminated, many organizations find barriers in their implementation and management. This study seeks to identify and evaluate the critical success factors in the implementation of Lean Thinking based on a qualitative research in the manufacturing environment of a multinational chemical company that produces acrylic tapes for the automotive market

Influência da cultura organizacional na implementação de um programa de melhoria contínua de uma empresa de grande porte

The objective of this study was to identify the facilitators and restrictive factors promoted by the organizational culture on the implementation of a continuous improvement program in a company. The influence of organizational culture on tools used to improve processes and results demonstrate critical factors for international competitiveness, reflecting a company's strategy. Depending on how new working methods are implemented, organizational changes to reduce variation and waste, such as lean production, can affect the employee experience in the workplace and their learning conditions. Changes and formalization of the work process can be coercive, characterized by forced compliance, introduction of rules, and focus on technical and financial methods; or may be favorable, encouraging employee involvement in problem solving and stressing learning and innovation. The basis of the analysis lies with two models for assessing organizational culture - Denison Model and Competing Values Framework. The methodology used was: conducting interviews, a questionnaire, literature review and documentary analysis of a large company equipment industry. Results suggest that organizational culture plays an important role in the adoption of Lean practices. It can contribute to its effectiveness and job satisfaction, but it is not decisive feature of their success. The conclusion is that the organizational culture becomes a driving factor when aligned to the proposed practices and when taken into consideration for planning, acting as a limitation when it does not promote development and a participative environment

Fatores críticos de sucesso na implementação e gerenciamento do pensamento enxuto: um estudo na manufatura de fitas acrílicas

As a result of the industrial competitiveness increase in recent decades, concern about process improvements has been growing significantly. Lean Thinking principles are being more and more applied in the different sectors of the industry and aim to reduce costs, which can generate satisfactory results for an organization. Besides the application of lean tools on workstations, Lean Thinking seeks cultural change of the employees. Although the concepts of this management philosophy are widely disseminated, many organizations find barriers in their implementation and management. This study seeks to identify and evaluate the critical success factors in the implementation of Lean Thinking based on a qualitative research in the manufacturing environment of a multinational chemical company that produces acrylic tapes for the automotive market

Influência da cultura organizacional na implementação de um programa de melhoria contínua de uma empresa de grande porte

The objective of this study was to identify the facilitators and restrictive factors promoted by the organizational culture on the implementation of a continuous improvement program in a company. The influence of organizational culture on tools used to improve processes and results demonstrate critical factors for international competitiveness, reflecting a company's strategy. Depending on how new working methods are implemented, organizational changes to reduce variation and waste, such as lean production, can affect the employee experience in the workplace and their learning conditions. Changes and formalization of the work process can be coercive, characterized by forced compliance, introduction of rules, and focus on technical and financial methods; or may be favorable, encouraging employee involvement in problem solving and stressing learning and innovation. The basis of the analysis lies with two models for assessing organizational culture - Denison Model and Competing Values Framework. The methodology used was: conducting interviews, a questionnaire, literature review and documentary analysis of a large company equipment industry. Results suggest that organizational culture plays an important role in the adoption of Lean practices. It can contribute to its effectiveness and job satisfaction, but it is not decisive feature of their success. The conclusion is that the organizational culture becomes a driving factor when aligned to the proposed practices and when taken into consideration for planning, acting as a limitation when it does not promote development and a participative environment

A configuration framework of manufacturing strategy paradigm in state owned enterprises within China's petrochemical industry:building context-embedded configurations for the paradigm of strategic manufacturing management from exploratory case studies

The role of the production system as a key determinant of competitive performance of business operations- has long been the subject of industrial organization research, even predating the .explicit conceptua1isation of manufacturing, strategy in the literature. Particular emergent production issues such as the globalisation of production, global supply chain management, management of integrated manufacturing and a growing e~busjness environment are expected to critically influence the overall competitive performance and therefore the strategic success of the organization. More than ever, there is a critical need to configure and improve production system and operations competence in a strategic way so as to contribute to the long-term competitiveness of the organization. In order to operate competitively and profitably, manufacturing companies, no matter how well managed, all need a long-term 'strategic direction' for the development of operations competence in order to consistently produce more market value with less cost towards a leadership position. As to the long-term competitiveness, it is more important to establish a dynamic 'strategic perspective' for continuous operational improvements in pursuit of this direction, as well as ongoing reviews of the direction in relation to the overall operating context. However, it also clear that the 'existing paradigm of manufacturing strategy development' is incapable of adequately responding to the increasing complexities and variations of contemporary business operations. This has been factually reflected as many manufacturing companies are finding that methodologies advocated in the existing paradigm for developing manufacturing strategy have very limited scale and scope for contextual contingency in empirical application. More importantly, there has also emerged a deficiency in the multidimensional and integrative profile from a theoretical perspective when operationalising the underlying concept of strategic manufacturing management established in the literature. The point of departure for this study was a recognition of such contextual and unitary limitations in the existing paradigm of manufacturing strategy development when applied to contemporary industrial organizations in general, and Chinese State Owned Enterprises (SOEs) in particular. As China gradually becomes integrated into the world economy, the relevance of Western management theory and its paradigm becomes a practical matter as much as a theoretical issue. Since China markedly differs from Western countries in terms of culture, society, and political and economic systems, it presents promising grounds to test and refine existing management theories and paradigms with greater contextual contingency and wider theoretical perspective. Under China's ongoing programmes of SOE reform, there has been an increased recognition that strategy development is the very essence of the management task for managers of manufacturing companies in the same way as it is for their counterparts in Western economies. However, the Western paradigm often displays a rather naive and unitary perspective of the nature of strategic management decision-making, one which largely overlooks context-embedded factors and social/political influences on the development of manufacturing strategy. This thesis studies the successful experiences of developing manufacturing strategy from five high-performing large-scale SOEs within China’s petrochemical industry. China’s petrochemical industry constitutes a basic heavy industrial sector, which has always been a strategic focus for reform and development by the Chinese government. Using a confirmation approach, the study has focused on exploring and conceptualising the empirical paradigm of manufacturing strategy development practiced by management. That is examining the ‘empirical specifics’ and surfacing the ‘managerial perceptions’ of content configuration, context of consideration, and process organization for developing a manufacturing strategy during the practice. The research investigation adopts a qualitative exploratory case study methodology with a semi-structural front-end research design. Data collection follows a longitudinal and multiple-case design and triangulates case evidence from sources including qualitative interviews, direct observation, and a search of documentations and archival records. Data analysis follows an investigative progression from a within-case preliminary interpretation of facts to a cross-case search for patterns through theoretical comparison and analytical generalization. The underlying conceptions in both the literature of manufacturing strategy and related studies in business strategy were used to develop theoretical framework and analytical templates applied during data collection and analysis. The thesis makes both empirical and theoretical contributions to our understanding of 'contemporary management paradigm of manufacturing strategy development'. First, it provides a valuable contextual contingency of the 'subject' using the business setting of China's SOEs in petrochemical industry. This has been unpacked into empirical configurations developed for its context of consideration, its content and process respectively. Of special note, a lean paradigm of business operations and production management discovered at case companies has significant implications as an emerging alternative for high-volume capital intensive state manufacturing in China. Second, it provides a multidimensional and integrative theoretical profile of the 'subject' based upon managerial perspectives conceptualised at case companies when operationalising manufacturing strategy. This has been unpacked into conceptual frameworks developed for its context of consideration, its content constructs, and its process patterns respectively. Notably, a synergies perspective towards the operating context, competitive priorities and competence development of business operations and production management has significant implications for implementing a lean manufacturing paradigm. As a whole, in so doing, the thesis established a theoretical platform for future refinement and development of context-specific methodologies for developing manufacturing strategy.

Virtual manufacturing:a study of some important issues relating to the transformation of traditional manufacturing organisations

This thesis starts with a literature review, outlining the major issues identified in the literature concerning virtual manufacturing enterprise (VME) transformation. Then it details the research methodology used – a systematic approach for empirical research. next, based on the conceptual framework proposed, this thesis builds three modules to form a reference model, with the purpose of clarifying the important issues relevant to transforming a traditional manufacturing company into a VME. The first module proposes a mechanism of VME transformation – operating along the VME metabolism. The second module builds a management function within a VME to ensure a proper operation of the mechanism. This function helps identify six areas as closely related to VME transformation: lean manufacturing; competency protection; internal operation performance measurement; alliance performance measurement; knowledge management; alliance decision making. The third module continues and proposes an alliance performance measurement system which includes 14 categories of performance indicators. An analysis template for alliance decision making is also proposed and integrated into the first module. To validate these three modules, 7 manufacturing organisations (5 in China and 2 in the UK) were investigated, and these field case studies are analysed in this thesis. The evidence found in these organisations, together with the evidence collected from the literature, including both researcher views and literature case studies, provide support for triangulation evidence. In addition, this thesis identifies the strength and weakness patterns of the manufacturing companies within the theoretical niche of this research, and clarifies the relationships among some major research areas from the perspective of virtual manufacturing. Finally, the research findings are summarised, as well as their theoretical and practical implications. Research limitations and recommendations for future work conclude this thesis.