Analysis of competitiveness level in an industrial company using a continuous improvement based approach

International audience

Análise e melhoria de processo de pintura e vulcanização na Continental

A indústria automóvel é um dos setores mais exigentes do mercado global, por este motivo empresas como a Continental Mabor S.A, líderes de mercado, necessitam estar na linha da frente no que toca a programas de melhoria contínua e de uma gestão orientada para um crescimento rentável e sustentado. Nesta perspetiva, este estudo de dissertação tem como objetivo encontrar uma solução para a gestão de stock e FiFo (First in First out) de pneus em verde na supracitada empresa, situada em Lousado, Vila Nova de Famalicão. Este projeto de dissertação iniciou-se com uma análise e diagnóstico do processo produtivo do pneu, entre a Construção e a Vulcanização. Nesta análise, foi possível identificar vários problemas, sendo o mais crítico associado à logística interna de transporte do pneu “em curso”, de fabrico entre as fases do mesmo, Construção e Vulcanização. Devido a condicionantes estruturais e de organização, a logística interna de transporte entre estes dois sectores enfrenta estrangulamentos nos fluxos, a falta de espaço para acomodar o material em curso, problemas organizacionais de controlo e monitorização do processo produtivo, dificuldades de regulação do fluxo e localização dos carros de transporte dos pneus em verde. Face aos problemas detetados ao longo do estudo, foram analisadas várias soluções para a resolução ou minimização dos mesmos. Entre as soluções propostas salientam-se: o alargamento do sistema de transporte por tapetes rolantes GTC (Green Tire Conveying) a todos os módulos de construção. Esta solução diminui o fluxo de carros para a área da construção, descongestionando a zona próxima do sistema de carregamento automático GTAL (Green Tire Automatic Loading) na vulcanização. A implementação dum sistema Wi-Fi RFID, que permite identificar e localizar artigos em curso utilizando etiquetas inteligentes numa rede wireless, conseguindo melhorar a programação de produção e o respetivo sequenciamento. Sabendo também que a Continental se encontra numa fase de expansão, designada Projeto Route 17/20, as soluções propostas tomaram em consideração essa nova realidade futura. Assim, foram estudados e propostos novos layouts para esse atual processo. Nestes novos layouts, procurou-se uma reorganização dos processos de fabrico, bem como um redimensionamento dos espaços de parqueamento de carros de pneus verdes adequado aos volumes produtivos. De igual forma, adequou-se os espaços físicos à possível implementação de um sistema de FiFo de pneus em verde na planta fabril, quando concluída a expansão. Este trabalho de dissertação apresenta como vantagens diretas da sua implementação: gerar a menor perturbação no atual método de trabalho seguido na empresa; previsivelmente aumentar a eficiência do processo produtivo; potenciar o crescimento tecnológico programado pela empresa; e oferecer uma boa relação custo/benefício no investimento necessário. Como apreciação final, pode-se concluir que este estudo foi finalizado com sucesso, visto que as soluções propostas foram apreciadas positivamente pela Administração da Continental Mabor S.A. e estão correntemente a ser avaliadas pelo grupo.

Aplicação do DMAIC em uma indústria farmacêutica

In an industry, being a big one or small one, the process improvement is always a focus for it to increase in the market. The improvement, if searched in a simple meaning, brings the unique meaning of change to better. However the meaning of process improvement can take much more than a superficial point of view. Kaizen, Process improvement, Continuous improvement, they are some denotations much more comprehensive of a such a term carried of so many meanings. A good concept of improvement if to search inside processes a more appropriate way, a more succinct, a more economic way to realize it. The idea is to make the process in a better way. In this graduation thesis, there will be presented a process improvement realized in a Vale do Paraíba company. For that, it was used the DMAIC to obtain, measure and control the process improvement. It should be noted that the goal is to present and discuss a process improvement

IDEA MANAGEMENT SYSTEM - AN ESSENTIAL COMPONENT IN THE CONTINUOUS IMPROVEMENT OF QUALITY AND INNOVATION

It is known the power of ideas is tremendous. But there are employees in many companies who have good ideas but not put them into practice. On the other hand, there are many others who have good ideas and are encouraged to contribute their ideas for innovation in the company. This study attempts to identify factors that contribute to success in managing ideas and consequent business innovation. The method used was the case study applied to two companies. During the investigation, factors considered essential for the success of an idea management program were identified, of which we highlight, among others, evidences the results, involvement of the top management, establishment of goals and objectives; recognition; dissemination of good results. Companies with these implemented systems, capture the best ideas from their collaborators and apply them internally. This study intends to contribute to business innovation in enterprises through creation and idea management, mainly through collecting the best ideas of their own employees. The results of this study can be used to help improving deployed suggestions systems, as well as, all managers who wish to implement suggestions systems/ideas management systems.

Theory of reasoned action for continuous improvement capabilities: a behavioral approach

The importance of interaction between Operations Management (OM) and Human Behavior has been recently re-addressed. This paper introduced the Reasoned Action Theory suggested by Froehle and Roth (2004) to analyze Operational Capabilities exploring the suitability of this model in the context of OM. It also seeks to discuss the behavioral aspects of operational capabilities from the perspective of organizational routines. This theory was operationalized using Fishbein and Ajzen (F/A) behavioral model and a multi-case strategy was employed to analyze the Continuous Improvement (CI) capability. The results posit that the model explains partially the CI behavior in an operational context and some contingency variables might influence the general relations among the variables involved in the F/A model. Thus intention might not be the determinant variable of behavior in this context.

Continuous improvement logidtics project: A study on the increase of the finished goods warehouse of Unilever at Sta. Iria

This project is called Improvement Logistics Project and aims to study an opportunity of expansion of the output in 80% of the Unilever warehouse at Sta. Iria via an increase in exportations for the next two years. This has been done using the Distibuidora Luís Simões tariff rates as basis of comparison for the as-is and to-be situations. For this matter, an allocation of all the costs of the warehouse is prepared and described with the goal of comparing the differences with and without expansion. The results show that a better outcome is achieved with the investment, but the warehouse is yet to prove its efficiency against the distribution company.

Contribution to a strategic plan for the implementation of continuous improvement process in an MRO

This Work Project studies the Continuous Improvement and Processes (CIP) department at TAP Maintenance & Engineering. The project has the objective to provide insights to align the activities of the department with the strategy of the organization. For such, two focuses were taken: (i) an internal analysis which highlighted a need for transversal change to ensure the adoption of Continuous Improvement at TAP, and (ii) a process which outlined objectives and projects to be pursued to prioritize CIP’s activities in accordance with the organization’s goals. The outcome includes (a) important recommendations concerning strategic planning and competition evaluation and (b) a process’ output that reflects a balance among factors influencing the priority of projects.

"The 3/3 strategy": a successful multifaceted hospital wide hand hygiene intervention based on WHO and continuous quality improvement methodology.

BACKGROUND Only multifaceted hospital wide interventions have been successful in achieving sustained improvements in hand hygiene (HH) compliance. METHODOLOGY/PRINCIPAL FINDINGS Pre-post intervention study of HH performance at baseline (October 2007-December 2009) and during intervention, which included two phases. Phase 1 (2010) included multimodal WHO approach. Phase 2 (2011) added Continuous Quality Improvement (CQI) tools and was based on: a) Increase of alcohol hand rub (AHR) solution placement (from 0.57 dispensers/bed to 1.56); b) Increase in frequency of audits (three days every three weeks: "3/3 strategy"); c) Implementation of a standardized register form of HH corrective actions; d) Statistical Process Control (SPC) as time series analysis methodology through appropriate control charts. During the intervention period we performed 819 scheduled direct observation audits which provided data from 11,714 HH opportunities. The most remarkable findings were: a) significant improvements in HH compliance with respect to baseline (25% mean increase); b) sustained high level (82%) of HH compliance during intervention; c) significant increase in AHRs consumption over time; c) significant decrease in the rate of healthcare-acquired MRSA; d) small but significant improvements in HH compliance when comparing phase 2 to phase 1 [79.5% (95% CI: 78.2-80.7) vs 84.6% (95% CI:83.8-85.4), p<0.05]; e) successful use of control charts to identify significant negative and positive deviations (special causes) related to the HH compliance process over time ("positive": 90.1% as highest HH compliance coinciding with the "World hygiene day"; and "negative":73.7% as lowest HH compliance coinciding with a statutory lay-off proceeding). CONCLUSIONS/SIGNIFICANCE CQI tools may be a key addition to WHO strategy to maintain a good HH performance over time. In addition, SPC has shown to be a powerful methodology to detect special causes in HH performance (positive and negative) and to help establishing adequate feedback to healthcare workers.

Continuous Quality Improvement Snow Plow Accident Study Report, 1995

Identify processes to modify in order to reduce snow plow accidents. Reviewed all [Iowa] D.O.T. snow plow accidents that occurred in calendar years 1992 and 1993.

Creating dynamic continuous improvement system for Larox Corporation

Today´s organizations must have the ability to react to rapid changes in the market. These rapid changes cause pressure to continuously find new efficient ways to organize work practices. Increased competition requires businesses to become more effective and to pay attention to quality of management and to make people to understand their work's impact on the final result. The fundamentals in continmuois improvement are systematic and agile tackling of indentified individual process constraints and the fact tha nothin finally improves without changes. Successful continuous improvement requires management commitment, education, implementation, measurement, recognition and regeneration. These ingredients form the foundation, both for breakthrough projects and small step ongoing improvement activities. One part of the organization's management system are the quality tools, which provide systematic methodologies for identifying problems, defining their root causes, finding solutions, gathering and sorting of data, supporting decision making and implementing the changes, and many other management tasks. Organizational change management includes processes and tools for managing the people in an organizational level change. These tools include a structured approach, which can be used for effective transition of organizations through change. When combined with the understanding of change management of individuals, these tools provide a framework for managing people in change,

Lean daily management, visual management and continuous improvement

This thesis was part of lean adaptation project started at Outotec Lappeenranta factory in early 2013. The purpose of this thesis was to develop and propose lean tools that could be used in daily management, visual management and continuous improvement. This thesis was “outsiders” view, and as such, did not study the current processes deeply. As result of this thesis, two different Daily Management -boards were designed, one for parallel processes and one for sequential processes. In addition, methods of doing continuous improvement and daily task accountability were framed and standard work for the leaders outlined. The tools presented in this thesis are general tools which support work in lean environment. They are visual and, if used correctly, they provide a basis from which continuous improvement can be done. Lean philosophy emphasizes the deep understanding of the current situation and it would be against the lean principles to blindly implement anything developed “on the outside”. The tools presented should be reviewed and modified further by the people working on the factory floor.

Continuous improvement programs as processes for organizational learning: a case study of a company in the food products industry

This article intends to show the relationships between quality practices and the process of organizational learning. When we look at the literature about programs of continuous improvement we see that theoreticians consider that the process of organizational learning is a superior stage in the quality culture adopted by companies. To investigate this possibility, we put together a series of indicators taken from classic authors who have written about organizational learning. Adopting a multiple methodology, we applied these indicators to two plants belonging to the Nestlé food product company which have introduced continuous improvement programs over the last two years.