Lean, Six Sigma ja Total Welding Management hitsaavassa verkostossa

Diplomityössä tarkastellaan hitsaavan verkoston laadunhallintaa ja siinä ilmeneviä erilaisia ongelmakohtia. Tämän lisäksi työssä tarkastellaan kolmen eri laatutyökalun Lean, Six Sigma ja Total Welding Management soveltamista hitsaavan verkoston laadunhallinnassa. Teoriaosassa käsitellään sekä yleisesti että hitsauksen osalta laatua ja laadunhallintaa, sekä edellä mainittuja laatutyökaluja. Tutkimusosaan tietoja hitsaavista verkostoista kerättiin kaikkiaan kolmesta eri verkostosta. Näiden kerättyjen tietojen pohjalta tarkasteltiin valittujen laatutyökalujen soveltuvuutta verkostomaiseen käyttöön. Verkostoitunut toiminta aiheuttaa monia uusia haasteita yritysten laadunhallinnalle verrattuna yksittäisiin hitsaaviin yrityksiin. Suurimpia tutkimuksessa havaittuja ongelmakohtia ovat suunnittelun ja valmistuksen yhteistyön erilaiset puutteet, laatutasoon ja sen varmistukseen liittyvät asiat, sekä verkoston sisälle syntyvä niin sanottu hiljainen tieto ja sen häviäminen. Tutkimuksen tarkastelujen perusteella havaittiin, että kaikkien tutkimukseen valitun kolmen laatutyökalun soveltaminen myös verkostomaisessa toiminnassa on mahdollista, mutta se vaatii huomattavasti suurempaa työpanosta kuin soveltaminen yksittäisessä yrityksessä. Myös näiden kaikkien kolmen työkalun yhtä aikainen käyttö on mahdollista. Juuri oikean työkalun valitseminen kullekin hitsaavalle verkostolle vaatii tarkkaa perehtymistä verkostoon ja sen tilanteeseen.

Excelling in procurement : IT Contract Management with Lean and Six Sigma. Case study on legacy contract management at Philips Global IT.

Few people see both opportunities and threats coming from IT legacy in current world. On one hand, effective legacy management can bring substantial hard savings and smooth transition to the desired future state. On the other hand, its mismanagement contributes to serious operational business risks, as old systems are not as reliable as it is required by the business users. This thesis offers one perspective of dealing with IT legacy – through effective contract management, as a component towards achieving Procurement Excellence in IT, thus bridging IT delivery departments, IT procurement, business units, and suppliers. It developed a model for assessing the impact of improvements on contract management process and set of tools and advices with regards to analysis and improvement actions. The thesis conducted case study to present and justify the implementation of Lean Six Sigma in IT legacy contract management environment. Lean Six Sigma proved to be successful and this thesis presents and discusses all the steps necessary, and pitfalls to avoid, to achieve breakthrough improvement in IT contract management process performance. For the IT legacy contract management process two improvements require special attention and can be easily copied to any organization. First is the issue of diluted contract ownership that stops all the improvements, as people do not know who is responsible for performing those actions. Second is the contract management performance evaluation tool, which can be used for monitoring, identifying outlying contracts and opportunities for improvements in the process. The study resulted in a valuable insight on the benefits of applying Lean Six Sigma to improve IT legacy contract management, as well as on how Lean Six Sigma can be applied in IT environment. Managerial implications are discussed. It is concluded that the use of data-driven Lean Six Sigma methodology for improving the existing IT contract management processes is a significant addition to the existing best practices in contract management.

Lean Six Sigma in a Manufacturing Lead Time Improvement Project

The objective of this research is to demonstrate the use of Lean Six Sigma methodology in a manufacturing lead time improvement project. Moreover, the goal is to develop working solutions for the target company to improve its manufacturing lead time. The theoretical background is achieved through exploring the literature of Six Sigma, Lean and Lean Six Sigma. The development will be done in collaboration with the related stakeholders, by following the Lean Six Sigma improvement process DMAIC and by analyzing the process data from the target company. The focus of this research is in demonstrating how to use Lean Six Sigma improvement process DMAIC in practice, rather than in comparing Lean Six Sigma to other improvement methodologies. In order to validate the manufacturing system’s current state, improvement potential and solutions, statistical tools such as linear regression analysis were used. This ensured that all the decisions were as heavily based on actual data as possible. As a result of this research, a set of solutions were developed and implemented in the target company. These solutions included batch size reduction, bottleneck shift, first-in first-out queuing and shifting a data entry task from production planners to line workers. With the use of these solutions, the target company was able to reduce its manufacturing lead time by over one third.

Customer Discovery and Customer Validation in Lean Software Startups

The traditional business models and the traditionally successful development methods that have been distinctive to the industrial era, do not satisfy the needs of modern IT companies. Due to the rapid nature of IT markets, the uncertainty of new innovations‟ success and the overwhelming competition with established companies, startups need to make quick decisions and eliminate wasted resources more effectively than ever before. There is a need for an empirical basis on which to build business models, as well as evaluate the presumptions regarding value and profit. Less than ten years ago, the Lean software development principles and practices became widely well-known in the academic circles. Those practices help startup entrepreneurs to validate their learning, test their assumptions and be more and more dynamical and flexible. What is special about today‟s software startups is that they are increasingly individual. There are quantitative research studies available regarding the details of Lean startups. Broad research with hundreds of companies presented in a few charts is informative, but a detailed study of fewer examples gives an insight to the way software entrepreneurs see Lean startup philosophy and how they describe it in their own words. This thesis focuses on Lean software startups‟ early phases, namely Customer Discovery (discovering a valuable solution to a real problem) and Customer Validation (being in a good market with a product which satisfies that market). The thesis first offers a sufficiently compact insight into the Lean software startup concept to a reader who is not previously familiar with the term. The Lean startup philosophy is then put into a real-life test, based on interviews with four Finnish Lean software startup entrepreneurs. The interviews reveal 1) whether the Lean startup philosophy is actually valuable for them, 2) how can the theory be practically implemented in real life and 3) does theoretical Lean startup knowledge compensate a lack of entrepreneurship experience. A reader gets familiar with the key elements and tools of Lean startups, as well as their mutual connections. The thesis explains why Lean startups waste less time and money than many other startups. The thesis, especially its research sections, aims at providing data and analysis simultaneously.

Customer Discovery and Customer Validation in Lean Software Startups

The traditional business models and the traditionally successful development methods that have been distinctive to the industrial era, do not satisfy the needs of modern IT companies. Due to the rapid nature of IT markets, the uncertainty of new innovations‟ success and the overwhelming competition with established companies, startups need to make quick decisions and eliminate wasted resources more effectively than ever before. There is a need for an empirical basis on which to build business models, as well as evaluate the presumptions regarding value and profit. Less than ten years ago, the Lean software development principles and practices became widely well-known in the academic circles. Those practices help startup entrepreneurs to validate their learning, test their assumptions and be more and more dynamical and flexible. What is special about today‟s software startups is that they are increasingly individual. There are quantitative research studies available regarding the details of Lean startups. Broad research with hundreds of companies presented in a few charts is informative, but a detailed study of fewer examples gives an insight to the way software entrepreneurs see Lean startup philosophy and how they describe it in their own words. This thesis focuses on Lean software startups‟ early phases, namely Customer Discovery (discovering a valuable solution to a real problem) and Customer Validation (being in a good market with a product which satisfies that market). The thesis first offers a sufficiently compact insight into the Lean software startup concept to a reader who is not previously familiar with the term. The Lean startup philosophy is then put into a real-life test, based on interviews with four Finnish Lean software startup entrepreneurs. The interviews reveal 1) whether the Lean startup philosophy is actually valuable for them, 2) how can the theory be practically implemented in real life and 3) does theoretical Lean startup knowledge compensate a lack of entrepreneurship experience. A reader gets familiar with the key elements and tools of Lean startups, as well as their mutual connections. The thesis explains why Lean startups waste less time and money than many other startups. The thesis, especially its research sections, aims at providing data and analysis simultaneously.

Lean Transition of Emerging Industrial Capability (LeanTEC)

Lean Transition of Emerging Industrial Capability (LeanTEC) program was a cooperative agreement between the Boeing Company and AFRL conducted from January 1998 to January 2002. The results of this program are documented in the Manual for Effective Technology Transition Processes included as an attachment to this report. This manual provides processes, procedures, and tools for greatly improving technology transition in the aerospace industry. Methodology for the implementation of these improvements is given along with methods for customizing the various processes, procedures, and tools for a given company or business unit. The indicated methodology was tested by the LeanTEC team and results are documented in the report.

Influence of surface texture on the galling characteristics of lean duplex and austenitic stainless steels

Two simulative test methods were used to study galling in sheet forming of two types of stainlesssteel sheet: austenitic (EN 1.4301) and lean duplex LDX 2101 (EN 1.4162) in different surface conditions. Thepin-on-disc test was used to analyse the galling resistance of different combinations of sheet materials and lubricants. The strip reduction test, a severe sheet forming tribology test was used to simulate the conditionsduring ironing. This investigation shows that the risk of galling is highly dependent on the surface texture of theduplex steel. Trials were also performed in an industrial tool used for high volume production of pumpcomponents, to compare forming of LDX 2101 and austenitic stainless steel with equal thickness. The forming forces, the geometry and the strains in the sheet material were compared for the same component.It was found that LDX steels can be formed to high strain levels in tools normally applied for forming ofaustenitic steels, but tool adaptations are needed to comply with the higher strength and springback of thematerial.

Lean startup: análise exploratória sobre sua utilização por novas empresas brasileiras

Recentemente diversos empreendedores passaram a empregar uma nova abordagem na criação de empresas, denominada “Lean Startup” que, começou a ser difundida no Brasil em 2012 com o livro de Eric Ries. Seguindo a perspectiva do empreendedorismo como método, ela representa uma ruptura nos estudos de empreendedorismo, pois é diferente da abordagem preditiva utilizada até então em que elabora-se um plano de negócios e, somente depois da busca de investimentos, o produto é testado com clientes. Embora muito utilizada, existem poucos estudos acadêmicos sobre as práticas Lean aplicadas a Startups, daí a relevância do presente estudo. Com caráter exploratório, a pesquisa utiliza uma metodologia quantitativa e se vale de uma survey, respondida por 115 empreendedores, sócios de empresas de base tecnológica com até 42 meses de existência, com o objetivo de descobrir se eles conhecem a Lean Startup, o quanto suas ferramentas são adotadas e se elas trazem efeitos positivos. Como resultado, constatou-se que a Lean Startup é amplamente conhecida e utilizada, foram encontradas sinalizações de resultados positivos obtidos pelo uso de algumas de suas ferramentas - feedback acelerado, produto mínimo viável (PMV) e métricas da contabilidade para inovação, que medem o aprendizado no lugar de lucro. Dessa forma, a pesquisa contribui com o aumento do conhecimento sobre a Lean Startup, bem como por meio da formulação de perguntas para direcionar estudo futuros.

Integração dos programas de melhoria Lean Manufacturing e Six Sigma aplicados à logística de transporte de produtos de uma indústria metalúrgica

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Otimização do processo de MRP (Material Requirement Planning) de embalagens: uma aplicação da metodologia lean six sigma em uma indústria de agronegócios

There is a growing search for continuous improvement within the companies which creates an obligation of reducing and when it is possible eliminating waste. Production Planning and Control Department (PCP) is not out of this question, making necessary the application of methods and creation of tools that eliminate steps which do not add value to the planning process. This paper aims to develop a tool which concentrates in just one place all the necessary information to make the packaging material requirement planning (MRP) in a agribusiness company. Besides, it also aims, in a more visual way and using devices that prevent mistakes (Poka-Yoke), to reduce the number of reviews and mistakes made by analysts. As a result, an Excel spreadsheet was developed. This spreadsheet shows what happens with the status of planning and receiving of packaging, giving some advices when some critical situation happens. The use of Lean Manufacturing Method and the action research method helped to well define the problem and to reduce the number of steps, spreadsheets and time of process in 80%, 60% and 75%, respectively

Lean six sigma como estratégia para o aumento de eficiência em laminação de alumínio

This study aims to assess the implementation of Lean Six Sigma in the preparation of plates and hot lamination process for a company of aluminum rolled products, to improve the quality, productivity and process efficiency. As a basis for achieving these goals, the DMAIC methodology and various quality tools such as Cause Effect Diagram, Process Flow, SIPOC, Pareto, FMEA and Control Chart were used, trying to propose improvements to processes and increase their efficiency. The results were significant and were the basis for the continuation of a continuous improvement project throughout the factory

Lean Six sigma aplicado a uma empresa do setor de embalagens

With the advent of a global economy, Lean Six Sigma meets the demand of new production process that creates products within the customer’s specification without any wastage. The objectives of this work is to use the concepts Lean Manufacturing and Six Sigma parallel to minimize costs, increase the customer base, reduce the delivery time which implies an increase in the turnover of products on the shelves in a packaging company. We used the DMAIC method to continue working. The method DMAIC indicated the main failure modes that were fixed in the step improve. At this stage the tools of Lean Manufacturing gain tremendous value by optimizing processes with defects. The conclusion involves an increase in monthly billing, a corporate restructuring and, finally, a renewal in how to conduct the work of management

Aplicação do lean six sigma na linha de produção de turbinas industriais a vapor

This work evaluates the implementation of Lean Six Sigma into the Steam Turbine’s Blades Manufacturing Process, aiming to improve productivity, quality and operational efficiency. Therefore, several tools have been applied, such as VSM, Spaghetti Diagram, Ishikawa, Pareto, DMAIC, Benchmarking and Control Charts, seeking to propose process improvements, as well as Quality Indicators creation. It was obtained a significant waste reduction throughout the process, achieving a lead time reduction of 42% and 83,41% in transport. Also, were introduced the Lean Thinking concepts, such as pull production and Continuous material flow. At the same time, it was possible to calculate the process capability and the sigma level, evaluating and proposing some improvements

Ferramentas do Lean Manufacturing aplicadas em uma indústria de luminária

Due to globalization, is increasingly common for companies to make their products more competitive. With this background, the industries seek more efficient ways to produce. This paper aims to examine the tools of Lean Manufacturing applied in an industry luminaries ,addressing the positive aspects. Were applied tools like value stream mapping, Kanban, setup reduction and 5S program. With the application of these tools obtained improvements in processes, reducing lead time from factory and reducing the cost of the luminaries

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