Análise envoltória de dados combinada com a lógica fuzzy em problemas de avaliação de eficiência de máquinas de consumo: um estudo em empresa do segmento farmacêutico

The pharmaceutical industry was consolidated in Brazil in the 1930s, and since then has become increasingly competitive. Therefore the implementation of the Toyota Production System, which aims to lean production, has become common among companies in the segment. The main efficiency indicator currently used is the Overall Equipment Effectiveness (OEE). This paper intends to, using the fuzzy model DEA-BCC, analyze the efficiency of the production lines of a pharmaceutical company in the Paraíba Valley, compare the values obtained by the model with those calculated by the OEE, identify the most sensitive machines to variation in the data input and develop a ranking of effectiveness between the consumer machinery. After the development, it is shown that the accuracy of the relationship between the two methods is approximately 57% and the line considered the most effective by the Toyota Production System is not the same as the one found by this paper

Redução de tempos de setup: aplicação de troca rápida de ferramentas em indústria de bebidas

The current competitive market requires companies to adapt so that they can meet the needs of customers in an agile manner and aimed at the lowest possible cost in their manufacture, be it a product or service. The Toyota Production System is aimed at higher profits through lean manufacturing practices with reduced spending, smaller lots and inventories, generated by market demand. The variety of products makes the setup of the equipment a critical point and it should be reduced as much as possible so it does not affect productivity. The rapid exchange of tools allows with few actions and a modification that time does not exceed one digit on your total time. In this study, a case study showed that only with standardization and use of cheap improvements made it possible to reduce setup time in bottle labeling machine by 98 minutes for a final time of approximately 10 minutes with little investment, demonstrating the feasibility the displayed and a monthly gain tool in bottles at approximately 120,000, generating a performance gain and budget of approximately R$ 94,000.00 per month

Análise envoltória de dados combinada com a lógica fuzzy em problemas de avaliação de eficiência de máquinas de consumo: um estudo em empresa do segmento farmacêutico

The pharmaceutical industry was consolidated in Brazil in the 1930s, and since then has become increasingly competitive. Therefore the implementation of the Toyota Production System, which aims to lean production, has become common among companies in the segment. The main efficiency indicator currently used is the Overall Equipment Effectiveness (OEE). This paper intends to, using the fuzzy model DEA-BCC, analyze the efficiency of the production lines of a pharmaceutical company in the Paraíba Valley, compare the values obtained by the model with those calculated by the OEE, identify the most sensitive machines to variation in the data input and develop a ranking of effectiveness between the consumer machinery. After the development, it is shown that the accuracy of the relationship between the two methods is approximately 57% and the line considered the most effective by the Toyota Production System is not the same as the one found by this paper

Manutenzione preventiva della Rail Line tramite il metodo MAGEC

L'elaborato è il risultato del progetto di tesi svolto presso l’azienda Lift Truck Equipment L.T.E. di Ostellato (Ferrara) che opera nell’ambito della progettazione e produzione di gruppi di sollevamento ed attrezzature per carrelli elevatori all’interno del gruppo Toyota Material Handling. Il progetto è stato svolto nel periodo da gennaio a marzo 2016 in collaborazione con l’ufficio di Ingegneria di processo di L.T.E. e riguarda l’applicazione del metodo MAGEC (Modi e Analisi dei Guasti e delle Criticità) per l’analisi dei guasti di una linea produttiva dell’azienda, la Rail Line. Nel primo capitolo viene inquadrato il sistema produttivo dell’azienda in aderenza con la filosofia del TPS (Toyota Production System) per chiarire l’ambito in cui è nato il progetto, le motivazioni che hanno portato al suo sviluppo e l’ottica secondo cui è stato svolto. Nel secondo capitolo è fornita una descrizione dell’approccio utilizzato, che consiste in una variante della FMECA, il metodo più utilizzato per le analisi in ambito affidabilistico. Inoltre sono riportate le attività di pianificazione che sono state svolte preliminarmente all’inizio del progetto. Successivamente nel terzo capitolo sono illustrati in modo dettagliato i vari step dell’implementazione del metodo, dalla raccolta dati, effettuata presso l’azienda, all’elaborazione. L’ultimo capitolo è dedicato ai risultati dell’analisi e a una breve descrizione di come tali risultati sono stati utilizzati nelle attività di manutenzione preventiva.

Transferring knowledge of manufacturing techniques within a subsidiary of a multi-national corporation

With the growth of the multi-national corporation (MNCs) has come the need to understand how parent companies transfer knowledge to, and manage the operations of, their subsidiaries. This is of particular interest to manufacturing companies transferring their operations overseas. Japanese companies in particular have been pioneering in the development of techniques such as Kaizen, and elements of the Toyota Production System (TPS) such as Kanban, which can be useful tools for transferring the ethos of Japanese manufacturing and maintaining quality and control in overseas subsidiaries. Much has been written about the process of transferring Japanese manufacturing techniques but much less is understood about how the subsidiaries themselves – which are required to make use of such techniques – actually acquire and incorporate them into their operations. This research therefore takes the perspective of the subsidiary in examining how knowledge of manufacturing techniques is transferred from the parent company within its surrounding (subsidiary). There is clearly a need to take a practice-based view to understanding how the local managers and operatives incorporate this knowledge into their working practices. A particularly relevant theme is how subsidiaries both replicate and adapt knowledge from parents and the circumstances in which replication or adaptation occurs. However, it is shown that there is a lack of research which takes an in-depth look at these processes from the perspective of the participants themselves. This is particularly important as much knowledge literature argues that knowledge is best viewed as enacted and learned in practice – and therefore transferred in person – rather than by the transfer of abstract and de-contextualised information. What is needed, therefore, is further research which makes an in-depth examination of what happens at the subsidiary level for this transfer process to occur. There is clearly a need to take a practice-based view to understanding how the local managers and operatives incorporate knowledge about manufacturing techniques into their working practices. In depth qualitative research was, therefore, conducted in the subsidiary of a Japanese multinational, Gambatte Corporation, involving three main manufacturing initiatives (or philosophies), namely 'TPS‘, 'TPM‘ and 'TS‘. The case data were derived from 52 in-depth interviews with project members, moderate-participant observations, and documentations and presented and analysed in episodes format. This study contributes to our understanding of knowledge transfer in relation to the approaches and circumstances of adaptation and replication of knowledge within the subsidiary, how the whole process is developed, and also how 'innovation‘ takes place. This study further understood that the process of knowledge transfer could be explained as a process of Reciprocal Provider-Learner Exchange that can be linked to the Experiential Learning Theory.

Transferring knowledge of manufacturing techniques in multinational corporations:preliminary findings

With the growth of the multinational corporation (MNC) has come the need to understand how parent companies transfer knowledge to, and manage the operations of, their subsidiaries. This is of particular interest to manufacturing companies transferring their operations overseas. Japanese companies in particular have been pioneering in this regard, with techniques such as the Toyota Production System (TPS) for transferring the ethos of Japanese manufacturing and maintaining quality and control in overseas subsidiaries. A great deal has been written about the process of transferring Japanese manufacturing techniques, but much less is understood about how the subsidiaries themselves, which are required to make use of such techniques, actually acquire and incorporate them into their operations. The research on which this paper is based therefore examines how, from the perspective of the subsidiary, knowledge of manufacturing techniques is transferred from the parent company. There is clearly a need to take a practice-based view to understanding how the local managers and operatives incorporate knowledge about manufacturing techniques into their working practices. In-depth qualitative research was, therefore, conducted in the subsidiary of a Japanese multinational, Denso Corporation, involving three main manufacturing initiatives (or philosophies), namely ‘TPS’, ‘TPM’ and ‘TS’. The case data were derived from 52 in-depth interviews with project members, moderate participant observations, and documentations. The aim of this paper is to present the preliminary findings from the case analyses. The research contributes to our understanding of knowledge transfer in relation to the circumstances of the selection between adaptation and replication of knowledge in the subsidiary from its parent. In particular this understanding relates to transfer across different flows and levels in the organisational hierarchy, how the whole process is managed, and also how modification takes place.

Stratégiai paradigmaváltás szervezeti verseny(képesség) és az Operations management központi szerepe (Central role of strategic paradigm change, corporate competitiveness and operations management)

Az elmúlt két évtized folyamán a menedzserek megtanultak a megújult szabályok szerint játszani. Tudatosították, hogy a vállalatuk eredményes navigálásához folyamatosan figyelniük és adaptálniuk kell a legújabb módszereket, elméleteket. Jelen tanulmányával a szerző ezt a folyamatot kívánja segíteni, valamint arra az alapvető kérdésre keresi a választ, hogy érdemes-e a rendkívül gyorsan változó világban hosszabb távú célok meghatározásával foglalkozni, és ha igen, akkor mire összpontosítsák a vállalatok erőfeszítéseiket. Milyen részletezettséggel, milyen módon határozzák meg az elképzeléseiket úgy, hogy közben megőrizzék a vállalat flexibilitását, a változások idején nélkülözhetetlen agilitást. A szerző arra vállalkozik, hogy feltárja a stratégiai paradigmaváltás fejlődését, a termelési stratégia, az operations management központi meghatározó szereppé válását, valamint áttekintse a termelési és szolgáltatási rendszervezetés (OM) elveinek, eszközeinek, módszereinek fejlődését, kölcsönhatását, összefüggéseit. _______ Change of paradigm has taken place in strategic planning. Fight for position turned into a fight of movement. Companies strive to achieve individual, not copyable organizational performance, as well as to realize their business strategies by means of value generating, proactive approach. Operative management now placed in the focus of production strategy is becoming the compass, the driving force of leadership. The management of production and service systems has grown into independent scientific disciplines. It yielded such principles, tools and methods which are present as world-renowned blueprints (scientific tools) in the field of maintaining and developing corporate performance. In the present study the author specifies and discusses the tools of operative management as criteria of value generation aiming at quality and cost efficiency. He analyses the backto- back character, interrelationship of quality, TQM (Total Quality Management), TPS (Toyota Production System) and JIT (Just in Time). He examines the effects thereof on corporate performance where significant and strong relationship can be demonstrated in case there is an ability to plan and develop new products. The current new OM (Operations Management) techniques increasingly rely upon the quality of human resources, the permanent improvement of procedures as well as focusing on tight cooperation with suppliers/customers. Supply chain management, core competence management, service management now represent a “new generation” of the OM methods, processes, serving at the same time as basis and starting point for expectable future techniques as well.

Princípios da construção enxuta no processo de planejamento de uma construtora de grande porte de Natal (RN)

Considered as one of the oldest activities done by men, the civil construction represents one of the most important sectors for the economic growth of a country, in spite of the low results of growth in the past few years and also in the current year. To make this industry grow, even with an unfavourable economic scenario, it is necessary to implement an effective planning in its activities. This is one of the most important concepts brought by the Lean Construction philosophy, which had its origin through the adaptation of the concepts established by the Toyota Production System (TPS) or Lean Production. By having as a scenario the city of Natal\RN, the main goal of this dissertation consists in investigating how the 11 principles of the lean construction influenced the schedule of a construction field that started to implement its lean concepts. As a methodology, it was used the case study of a big enterprise located in Natal (RN). During the execution of the method, documents related to the short-term, midterm and long-term planning were analysed , aiming to describe its planning process; it was also described the factors that caused the delays at the enterprises’ field ;in addition, a comparison was made between the results obtained at the case study and the ones presented at the literature; in the end, the actions were listed by the company, which had the purpose to solve the main causes of delays, verifying if they were linked to the lean construction principles. This research finds its reason of existence in the relevance of its theme at the nowadays reality of the construction industry, since the principles of the lean construction uphold the reduction of processes that are useless, diminishing wastes as well as costs in construction. The relevance is perceived for the academy, in terms of the possibility to discuss if the concepts established by the lean production are being adapted to the civil construction sector and how this adaptation is influencing at the buildings planning project. Economic importance, because with the reduction of the wastes and costs, the companies may reduce the building´s value into a more accessible value, even with the sector´s lower growth. And social significance, because lean construction gives a better participation of the labour at the planning activity. Among the main results, the high frequency of planning errors stands out, mainly the programming deviations and not the task programming, as well as the execution errors, low productivity and activities executed by the workers. Amongst the 11 principles of lean construction, only five were related with the 12 actions analysed by the author. From the 12 actions, four were completely cohesive to one or more from these five principles. Some improvement proposals were also highlighted and established by the research.

BIODIESEL PRODUCTION FROM DIFFERENT FEEDSTOCKS IN PILOT SCALE SYSTEM

In this study, the preparations of biodiesel from three different feedstocks, including rapeseed oil, high acidified Chinese wood oil and trap grease, were carried out in a pilot scale of 200 t yr(-1) biodiesel production system. The optimum operating conditions for transesterification of rapeseed oil in plug flow reactor were found to be as follows: the catalyst dosage is 1.2 wt%; the retention time is about 17 min; the bed temperature is 65 degrees C; the oil/methanol ratio is 1:6; the content of methyl ester is 96.33% under these conditions. A kind of ion exchange resin, a solid acid catalyst, filled in the fixed bed reactor was used as the esterification catalyst for the pretreating of high acidified oil. The acid value of Chinese wood oil could be reduced from 7 to 0.8 mg KOH.g(-1) after 88 min, the optimum operating conditions were obtained as follow: molar ratio of methanol to oil is about 6:1, the temperature of the fixed bed, 65 degrees C and the retention time, about 88 min. Also a kind of acidified oil, namely trap grease, with the acid value being 114 mg KOH.g(-1) could be equally converted to a good biodiesel product through this system. Generally, the refined biodiesel product generated through this system could meet China #0 Biodiesel Standard, as well as Germany Biodiesel Standard for most indexes. It indicates that the designed process in this system has a good adaptability for different kinds of oil.

Food intake, milk production, and tissue changes of Holstein-Friesian and Jersey x Holstein-Friesian dairy cows within a medium-input grazing system and a high-input total confinement system

Although interest in crossbreeding within dairy systems has increased, the role of Jersey crossbred cows within high concentrate input systems has received little attention. This experiment was designed to examine the performance of Holstein-Friesian (HF) and Jersey x Holstein-Friesian (J x HF) cows within a high concentrate input total confinement system (CON) and a medium concentrate input grazing system (GRZ). Eighty spring-calving dairy cows were used in a 2 (cow genotype) x 2 (milk production system) factorial design experiment. The experiment commenced when cows calved and encompassed a full lactation. With GRZ, cows were offered diets containing grass silage and concentrates [70:30 dry matter (DM) ratio] until turnout, grazed grass plus 1.0 kg of concentrate/day during a 199-d grazing period, and grass silage and concentrates (75:25 DM ratio) following rehousing and until drying-off. With CON, cows were confined throughout the lactation and offered diets containing grass silage and concentrates (DM ratio; 40:60, 50:50, 40:40, and 75:25 during d 1 to 100, 101 to 200, 201 to 250, and 251 until drying-off, respectively). Full-lactation concentrate DM intakes were 791 and 2,905 kg/cow for systems GRZ and CON, respectively. Although HF cows had a higher lactation milk yield than J x HF cows, the latter produced milk with a higher fat and protein content, so that solids-corrected milk yield (SCM) was unaffected by genotype. Somatic cell score was higher with the J x HF cows. Throughout lactation, HF cows were on average 37 kg heavier than J x HF cows, whereas the J x HF cows had a higher body condition score. Within each system, food intake did not differ between genotypes, whereas full-lactation yields of milk, fat plus protein, and SCM were higher with CON than with GRZ. A significant genotype x environment interaction was observed for milk yield, and a trend was found for an interaction with SCM. Crossbred cows on CON gained more body condition than HF cows, and overall pregnancy rate was unaffected by either genotype or management system. In summary, milk and SCM yields were higher with CON than with GRZ, whereas genotype had no effect on SCM. However, HF cows exhibited a greater milk yield response and a trend toward a greater SCM yield response with increasing concentrate levels compared with the crossbred cows.

Dimensionar a logística interna da fábrica Toyota Ovar para a produção de nova viatura

O projeto foi realizado na Toyota (divisão fabril de Ovar), no ano letivo 2014/2015, teve por base um estágio extracurricular que foi realizado para que desta forma tomasse contacto com uma realidade concreta e absoluta no contexto empresarial. O estágio serviu, principalmente, como uma experiência na compreensão do funcionamento de uma indústria de automóveis. Este projeto desenvolve-se no âmbito do 2ºano do Mestrado de Logística e apresenta os contributos desenvolvidos no departamento de logística para a reorganização da mesma para a produção de um novo modelo automóvel. Atualmente, a Toyota, para os modelos de automóveis que produz, recebe os componentes em CKD (Completed Knocked Down) provenientes do Japão em lotes de cinco unidades. Estes lotes são armazenados no armazém, de onde só saem quando for dada ordem para serem produzidos. Cada lote tem várias caixas, que são colocadas à vez numa zona comum de abertura. São retidos os componentes das caixas CKD e colocados nos transportadores próprios dos postos correspondentes (supermercado de linha). Isto significa que sempre que é solicitado uma viatura de um determinado lote, são obrigados a produzir as cinco unidades. Isto significa que as restantes unidades do lote terão que ficar em parque aberto a aguardar venda futura, para além de ter um stock desnecessário, estas unidades ficam vulneráveis e sofrem desgaste, pois estão expostas à intempérie, causando graves problemas de qualidade e respetivos custos associados. Recentemente, foi decidida a produção do modelo Land Cruiser 70 na unidade industrial de Ovar, Portugal, o que obrigou a uma reorganização da produção e processos logísticos para a sua produção. Os objetivos que a empresa pretende com a entrada de um novo projeto Land Cruiser 70, são os seguintes: Alterar o sistema de abastecimento, implementando o abastecimento unitário em toda a fábrica para o novo modelo, garantindo o “one by one production”; Definir o funcionamento do processo logístico desde a chegada dos componentes até ficarem disponíveis no supermercado de linha. Para isso será necessário dimensionar armazém e zona de abertura, definir layouts e quantidade de stocks, bem como definir sistemas de comunicação entre abertura e supermercado; Verificar as peças que vão fazer parte do chassi por posto e contabilizar os dolly´s1 necessários; Fazer o layout de abastecimento da linha do chassi; Calcular o tempo de abertura, de abastecimento e de picking do chassi e de triming. Este projeto tem em conta a política de melhoria contínua de forma a conseguir satisfazer o cliente (ser eficaz) utilizando cada vez menos recursos quer físicos quer humanos (ser eficiente, detetar e eliminar os desperdícios). O presente projeto foi inserido na equipa de melhoria contínua da logística, maioritariamente no chassi. Em termos globais, os objetivos propostos neste estágio foram atingidos com êxito.

The viability of commercial tomato production in the Autopot system

An investigation of the viability of commercial tomato production using the Autopot growing system in Australia. The Autopot system is a relatively new hydroponic production system technology that is being introduced onto the market in competition with traditional systems. Although commercial tomato production was found to be significantly more water and nutrient efficient in the Autopot system than in a traditional open system, yields were significantly lower. Financial modelling shows that tomato production in this system would not be commercially viable in Australia for a typical tomato growing venture under current conditions.

Dairy goat health management and milk production on organic and conventional system in Brazil

The aimed of this article is to measure risk factors on health and milk production on organic and conventional dairy goats in Brazil. Two experimental groups (organic and conventional) were evaluated simultaneously. The study design was completely randomized. The organic herd consisted of 25 goats and 15 kids. In the conventional production system, a dairy herd comprising 40 goats and 20 kids participated in the study. Data on milk production and health management were available from January 2007 to December 2009. The abortion rate in the conventional system was 5% (2/40) whereas in organic system no abortion was diagnosed (0/25). The mortality rate at weaning in the conventional system was 5% (2/40) and in the organic system was 8% (2/25). Milk production was lower (2.20 kg/day) in organic than conventional system (2.66 kg/day). Goats and kids in organic farm had a higher FEC (386±104 and 900±204, respectively) (p<0.05) than those in conventional farm (245±132 and 634±212, respectively). In addition, Saanen kids had higher FEC (p<0.001) than goats. Treatment with antiparasitic drugs was higher in conventional system (50%) than organic system (1.3%).

Reference model for implementing an MRP system in a highly diverse component and seasonal lean production environment

Companies are currently choosing to integrate logics and systems to achieve better solutions. These combinations also include companies striving to join the logic of material requirement planning (MRP) system with the systems of lean production. The purpose of this article was to design an MRP as part of the implementation of an enterprise resource planning (ERP) in a company that produces agricultural implements, which has used the lean production system since 1998. This proposal is based on the innovation theory, theory networks, lean production systems, ERP systems and the hybrid production systems, which use both components and MRP systems, as concepts of lean production systems. The analytical approach of innovation networks enables verification of the links and relationships among the companies and departments of the same corporation. The analysis begins with the MRP implementation project carried out in a Brazilian metallurgical company and follows through the operationalisation of the MRP project, until its production stabilisation. The main point is that the MRP system should help the company's operations with regard to its effective agility to respond in time to demand fluctuations, facilitating the creation process and controlling the branch offices in other countries that use components produced in the matrix, hence ensuring more accurate estimates of stockpiles. Consequently, it presents the enterprise knowledge development organisational modelling methodology in order to represent further models (goals, actors and resources, business rules, business process and concepts) that should be included in this MRP implementation process for the new configuration of the production system.

Use of the piggyBac transposon to create HIV-1 gag transgenic insect cell lines for continuous VLP production

Background Insect baculovirus-produced Human immunodeficiency virus type 1 (HIV-1) Gag virus-like-particles (VLPs) stimulate good humoral and cell-mediated immune responses in animals and are thought to be suitable as a vaccine candidate. Drawbacks to this production system include contamination of VLP preparations with baculovirus and the necessity for routine maintenance of infectious baculovirus stock. We used piggyBac transposition as a novel method to create transgenic insect cell lines for continuous VLP production as an alternative to the baculovirus system. Results Transgenic cell lines maintained stable gag transgene integration and expression up to 100 cell passages, and although the level of VLPs produced was low compared to baculovirus-produced VLPs, they appeared similar in size and morphology to baculovirus-expressed VLPs. In a murine immunogenicity study, whereas baculovirus-produced VLPs elicited good CD4 immune responses in mice when used to boost a prime with a DNA vaccine, no boost response was elicited by transgenically produced VLPs. Conclusion Transgenic insect cells are stable and can produce HIV Pr55 Gag VLPs for over 100 passages: this novel result may simplify strategies aimed at making protein subunit vaccines for HIV. Immunogenicity of the Gag VLPs in mice was less than that of baculovirus-produced VLPs, which may be due to lack of baculovirus glycoprotein incorporation in the transgenic cell VLPs. Improved yield and immunogenicity of transgenic cell-produced VLPs may be achieved with the addition of further genetic elements into the piggyBac integron.