Дисертації з теми "Manufacturing diagram"

This diploma thesis deals with the issue of material flow and lean manufacturing in a given section of a selected manufacturing company. The diploma thesis focuses on the weaknesses of the current state of the selected workplace and defines the areas for improvement. The first part presents the theoretical basis of the work. The second part of the work is focused on analyzing the current state of the workplace. There are provided solutions for better material flow and to implement selected elements of lean manufacturing in the last part.

A nivel mundial se sabe que, con el transcurrir de los años la industria del sector plástico se mueve en un nivel de crecimiento que está relacionado principalmente a su amplia capacidad de transformación, combinación, durabilidad y otras aplicaciones que si son correctamente empleados contribuyen a mejorar la capacidad de competitividad de las organizaciones haciendo frente a otros convertidores. Sin embargo, esta situación creciente genera que los procesos productivos se encuentren más saturado generando mayores registros de pérdidas en tiempo que impacta en el incumplimiento de la demanda, y ya que las fábricas de producción plástica venden tiempo de máquina esta situación afecta la rentabilidad de la misma. Para poder mitigar estas situaciones se han realizado diversos esfuerzos surgiendo filosofías y metodologías que permitan encontrar la solución a estos problemas, debido a la gran importancia que tiene para las empresas trabajar con la mayor eficiencia en sus procesos y con ello buscar incrementar su disponibilidad productiva para incrementar el volumen de ventas. En tal sentido, se aborda la implementación de la metodología Lean Manufacturing aplicada bajo el soporte del ciclo Deming y cuyo objetivo principal será desarrollar una estrategia en base al ciclo PHVA que permitirá incrementar la eficiencia de máquina de manera sostenida. Su aporte se desarrolla en torno a la aplicación exitosa de la combinación de las herramientas Lean seleccionadas bajo el esquema Deming y desarrolladas bajo un cronograma de Gantt para la solución del caso y que se desarrollan en este artículo pudiendo servir de guía inicial a otros técnicos que buscan incrementar la productividad de sus procesos en otras fábricas del sector.
Worldwide, it is known that, over the years, the industry of the plastic sector is moving at a level of growth that is mainly related to its broad capacity for transformation, combination, durability and other applications that, if correctly used, contribute to improving the capacity of competitiveness of organizations facing other converters. However, this growing situation means that production processes are more saturated, generating higher losses in time that impact on non-compliance with demand, and since plastic production plants sell machine time, this situation affects the profitability of the same In order to mitigate these situations, various efforts have been made to come up with philosophies and methodologies that allow finding the solution to these problems, due to the great importance for companies to work with the highest efficiency in their processes and thus seek to increase their productive availability to increase sales volume In this regard, the implementation of the Lean Manufacturing methodology applied under the support of the Deming cycle whose main objective will be to develop a strategy based on the PHVA cycle that will increase machine efficiency in a sustained manner is approached. Its contribution is developed around the successful application of the combination of the Lean tools selected under the Deming scheme and developed under a Gantt timetable for the solution of the case and that are developed in this article, being able to serve as an initial guide to other technicians who They seek to increase the productivity of their processes in other factories in the sector.
Trabajo de investigaciòn

The goal of this diploma thesis is to use the principles of lean manufacturing to lean workplace and eliminate all forms of waste in this workplace. A part of this work is opti-mal design of the workplace in terms of ergonomics which should have a positive effect on shortening lead time and process cycle efficiency. Shortening the lead time will allow company to respond more quickly to customer requirements and this effect may subsequently lead to the drop in inventories.

The work is focused on improving the concept of lean management in a selected engineering company, where analyzes are performed with the help of selected methods and tools to reveal current problems. The data are then processed and based on them, measures for change are proposed with an emphasis on minimizing the rate of waste of time and costs and increasing production efficiency.

La malnutrition est une menace importante pour la santé humaine. Au Togo, la purée de niébé appelée localement « Adowè » et potentiellement riche en nutriments peut servir à lutter contre la malnutrition déficitaire. Cependant, force est de constater que la sphère de production et de consommation de cette purée ne cesse de se réduire au fil des ans. Les présents travaux de thèse sur « Adowè » ont donc pour objectifs : (i) de contribuer à la lutte contre la carence nutritionnelle protéino-calorique par l’exploitation des agroressources endogènes comme le niébé (protéines végétales), (ii) de préserver l’environnement face à un rythme croissant de la consommation des protéines animales dans le monde. De ce fait, la valorisation et la réhabilitation de « Adowè » nous ont conduit à l’étude de sa production à l’échelle industrielle. La compression mécanique des graines de niébé pour déterminer leurs états cuits et les propriétés rhéologiques de la purée « Adowè » ont également été examinées dans cette thèse. Les résultats obtenus ont montré que l’état cuit des graines peut être évalué par des grandeurs physiques. L’énergie d’activation de cuisson des graines a également été déterminée. Ainsi, ces paramètres permettront de contrôler énergétiquement le procédé de cuisson des graines. La caractérisation rhéologique de la purée a montré un fluide à seuil pour les purées dont la concentration massique se situe entre 12 et 20%. Au-delà de 20% de concentration, la méthode de mesure de la viscosité par rotation pour la caractérisation rhéologique de « Adowè » n’est pas applicable. De ce fait, la méthode d’extrusion inverse a été exploitée pour quantifier la viscosité de « Adowè » à 31 ± 2 % (masse/masse). Ces résultats sont très intéressants et pourront être utiles pour un passage de la production artisanale à une production industrielle de « Adowè »
Malnutrition is a significant threat to human health. In Togo, cowpea puree, known locally as "Adowè", is potentially rich in nutrients and can be used to fight against malnutrition. However, this puree has seen reduced production and consumption over time. The aim of this thesis is to contribute to the fight against protein-calorie malnutrition through the use of endogenous agricultural resources, such as cowpea seeds (plant proteins). In a world where animal proteins consumption is on the rise, this work also helps to contribute towards environmental preservation. Therefore, promoting the development and rehabilitation of "Adowè" requires us to study its production on an industrial scale. Experiments were carried out to determine the cooked state of the cowpea seeds by mechanical compression. The rheological properties of the "Adowè" puree were also determined. The results obtained show that the cooked state of the seeds could be assessed by physical quantities. The activation energy for the cooking of theseeds has also been determined. These parameters will therefore be the basis for the energetic control of the seed cooking process. Finally, the rheological characterisation of the puree was carried out using two methods. For purees with mass concentrations between 12 and 20%, "Adowè" is a yield stress fluid. Beyond 20% concentration, oscillatory and steady shear viscosity measurements of the puree become intractable. Therefore, back extrusion method was used to quantify the viscosity of the puree at 31±2% (mass/mass). These results are useful fortransitioning from artisanal to industrial production of "Adowè"

Stoneridge, Inc. is an independent designer and manufacturer of highly engineered electrical and electronic components, modules and systems principally for the automotive, commercial vehicle, motorcycle, agricultural and off-highway vehicle markets. A subsidiary of Stoneridge, Inc. is the company Stoneridge Electronics. They specialise in instrument clusters and tachographs which are manufactured in high quantityin their production plant in Örebro, Sweden. This master thesis focuses on the production line of an instrument cluster called Angela. In close collaboration with Stoneridge Electronics, the goal was to find ways to improve the output of the Angela line by at least 10% compared to the three best months in terms of output from the year before. The Angela line was analyzed thoroughly and from different perspectives using lean tools such as value stream mapping, spaghetti diagram and continuous improvement. Finally, the simulation software ExtendSim was used in order to simulate and analyse different suggestions. The results show that various steps can be taken to improve the efficiency and output of the manufacturing line by as much as 16.3%. Due to the fact that other production lines within the production are similar to the one that the project was carried out on, the project results could be applicable for the other lines as well.
Stoneridge, Inc. är en oberoende designer och tillverkare av högteknologiska elektriska och elektroniska komponenter, moduler och system huvudsakligen för fordonsmarknaderna. Ett dotterbolag till Stoneridge, Inc. är företaget Stoneridge Electronics. De är specialiserade på instrument kluster och färdskrivare som tillverkas i produktionsanläggning i Örebro. Denna examensarbete fokuserar på produktionslinje av ett instrumentkluster som heter Angela. I nära samarbete med Stoneridge Electronics,målet var att hitta sätt att förbättra produktionen av Angela linje med minst 10 % jämförtmed de tre bästa månaderna när det gäller produktion från året innan. Angela-linjen analyserades grundligt och från olika perspektiv med lean verktyg som värdeflödesanalys, spaghetti diagram och kontinuerlig förbättring. Slutligen användes simuleringsprogrammet ExtendSim för att simulera och analysera olika förslag. Resultaten visar att olika steg kan vidtas för att förbättra effektiviteten och produktionen av produktionslinjen med så mycket som 16.3%. På grund av att andra produktionslinjer inom produktionen liknar den som projektet genomfördes på, kan projektresultaten vara tillämpliga för andra linjer också.

The aim of this thesis is to analyze the current state of the manufacturing process of the company ALFA s.r.o. Moravská Třebová, to submit own suggestions for the introduction of lean production to save time, costs and strengthening of the quality in the company and establish the conditions of implementation, in which is possible to implement specified proposals. The operational objective is also an explanation of benefits that gets the company after implementation of these proposals. The first part gives an overview of lean manufacturing methodologies and with using of selected methods and workflow analysis are determined in the second part the proposals. After their implementation the company can save time, reduce costs and strengthen quality for the customer as a basis for the introduction of lean manufacturing enterprise.

The aim of this diploma thesis is to create and apply a methodology to improve the manufacturing process. Processes for the passage of a contract through the company and activities of the foreman were analyzed. According to this analysis, a methodology was created for continuous improvement of the manufacturing process. This methodology was applied to the data obtained in the analysis. Based on the application of the methodology, actions have been proposed to improve the production process.

The master thesis: „ The Study of Optimization of Production Process“ focouses on optimization of material flow to manufacturing department. First of all there will be shown theoretical approach corresponding with the thesis area and we will introduce production system and portfolio of products. Subsequently a real project will be analyzed and author will describe deficiencies in this project and system. Thanks to theoretical approach there will be found a different solution how to define new system without deficiencies. In the end the author will make a conclusion of newly found solution

La principale difficulté lors de l'administration orale d'un ingrédient pharmaceutique actif (API) est de garantir que la dose clinique de l’API sera dissoute dans le volume disponible de liquides gastro-intestinaux. Toutefois, environ 40% des API sur le marché et près de 90% des molécules en cours de développement sont peu solubles dans l’eau et présentent une faible absorption par voie orale, ce qui entraîne une faible biodisponibilité. Les dispersions solides amorphes (ASD) sont considérées comme l’une des stratégies plus efficaces pour résoudre des problèmes de solubilité des principes actifs peu solubles dans l’eau et, ainsi, améliorer leur biodisponibilité orale. En dépit de leur introduction il y a plus de 50 ans comme stratégie pour améliorer l’administration orale des API, la formation et la stabilité physique des ASD font toujours l'objet de recherches approfondies. En effet, plusieurs facteurs peuvent influer sur la stabilité physique des ASD pendant le stockage, parmi lesquels la température de transition vitreuse du mélange binaire API-polymère, la solubilité apparente de l'API dans le polymère, les interactions entre l'API et le polymère et le procédé de fabrication. Cette thèse consistait en deux parties qui avaient pour objectif le développement de nouvelles formulations sous forme d’ASD d'un antirétroviral, l'Efavirenz (EFV), dispersé dans un polymère amphiphile, le Soluplus, en utilisant deux procédés différents, le séchage par atomisation (SD) et l'extrusion à chaud (HME). EFV est l’API BCS de classe II de notre choix car c’est un API qui représente un défi pour les nouvelles formulations. En effet, il a besoin d’ASD plus fortement concentrées, pour lesquelles la stabilité chimique et physique pendant le stockage et la dissolution seront essentielles. Dans le but de développer de manière rationnelle les ASDs EFV- Soluplus à forte concentration, la première partie s'est concentrée sur la construction d'un diagramme de phases EFV-Soluplus en fonction de la composition et de la température. Le diagramme de phases a été construit à partir d'une étude thermique de recristallisation d'un ASD sursaturé (85 %m EFV), générée par séchage par atomisation. À notre connaissance, il s'agit de la première étude à présenter un diagramme de phase pour ce système binaire. Ce diagramme de phases est très utile et démontre que la solubilité de l'EFV dans les solutions varie de 20 %m (25 °C) à 30 %m (40 °C). Les ASD de EFV dans le Soluplus contenant plus de 30 %m d'EFV doivent être surveillées pendant le stockage dans des conditions typiques de température. Ce diagramme de phases peut être considéré comme un outil de pré-formulation pour les chercheurs qui étudient de nouvelles ASD d'EFV dans le Soluplus afin de prédire la stabilité (thermodynamique et cinétique). Les ASD préparées par différentes techniques peuvent afficher des différences dans leurs propriétés physicochimiques. La deuxième partie de cette thèse portait sur la fabrication d’ASD par des procédés HME et SD. Cette étude montre clairement que la formation d’ASD est une stratégie de formulation utile pour améliorer la solubilité dans l'eau et la vitesse de dissolution de l'EFV à partir de mélanges binaires EFV-Soluplus. Les procédés de fabrication (HME et SD) se sont révélés efficaces pour générer des ASD dans une large gamme de compositions en EFV. L'optimisation du ratio EFV-Soluplus peut être utilisée pour adapter la libération cinétique des ASD. Le choix d’une charge EFV élevée dépassant la solubilité thermodynamique de l’EFV dans le Soluplus est possible, mais il convient de prendre en compte sa stabilité cinétique dans le temps
The main difficulty when an Active Pharmaceutical Ingredient (API) is orally administered is to guarantee that the clinical dose of the API will be dissolved in the available volume of gastrointestinal fluids. However, about 40% of APIs with market approval and nearly 90% of molecules in the discovery pipeline are poorly water-soluble and exhibits a poor oral absorption, which leads to a weak bioavailability. Amorphous solid dispersions (ASD) are considered as one of the most effective strategies to solve solubility limitations of poorly-water soluble compounds and hence, enhance their oral bioavailability. Despite their introduction as technical strategy to enhance oral APIs bioavailability more than 50 years ago, ASD formation and physical stability remains a subject of intense research. Indeed, several factors can influence the physical storage stability of ASD, among them, the glass transition temperature of the API-carrier binary mixture, the apparent solubility of the API in the carrier, interactions between API and carrier, and the manufacturing process. This thesis consisted of two parts that aim on developing new formulations of ASD of an antiretroviral API, Efavirenz (EFV), dispersed in an amphiphilic polymer, Soluplus, by using two different processes, Spray-drying (SD) and Hot-melt extrusion (HME). EFV is the class II BCS API of our choice because it is a challenging API for new formulations. It needs higher-dosed ASDs, for which chemical and physical stability during storage and dissolution will be critical. Aiming a rational development of high-loaded EFV-Soluplus ASDs, the first part focused on the construction of a temperature- composition EFV-Soluplus phase diagram. The phase-diagram was constructed from a thermal study of recrystallization of a supersaturated ASD (85 wt% in EFV), generated by spray drying. To our knowledge, this is the first study reporting a phase-diagram for this binary system. This phase-diagram is very useful and demonstrated that the EFV solubility in Soluplus ranges from 20 wt% (25 °C) to 30 wt% (40 °C). ASD of EFV in Soluplus containing more than 30 wt% of EFV should be monitored over storage under typical temperature conditions. This phase-diagram might be considered as a preformulation tool for researchers studying novel ASD of EFV in Soluplus, to predict (thermodynamic and kinetic) stability. ASD prepared by different techniques can display differences in their physicochemical properties. The second part of this thesis focused on the manufacturing of ASD by HME or SD processes. This study clearly shows that ASD is a useful formulation strategy to improve the aqueous solubility and the dissolution rate of EFV from EFV-Soluplus binary mixtures. HME and SD manufacturing processes demonstrated to be efficient to generate ASDs in a large range of compositions and loads of EFV. The optimization of EFV to Soluplus ratio can be used to tailor the release kinetics from ASD. The choice of a high EFV load exceeding the thermodynamic solid solubility in Soluplus is possible but it needs the consideration of its kinetic stability over time

This Master's thesis deals with the optimization of the material flow between two areas of the production plant of the selected company. At the beginning of the thesis there is shown theoretical framework which is needed for subsequent analysis and determination of the proposals to improvement. In this part there is pointed out to the understanding of the process and the various concepts related to the process management. Furthermore, for the purposes of the application part there are selected and analyzed specific tools of lean manufacturing. These include for example the spaghetti diagram, the product / process matrix and the value stream mapping as the essential tool of this thesis. All this is complemented by ABC analysis. After that these methods are also applied in the practical part for solving the current project in the selected company. At first in solving the project there is dealt with the determination of the most problematic material flow between two areas of production plant. Then there is suggested the optimization solutions and all of this is also complemented by the economic evaluation of the whole project.

The master Thesis deals with the layout optimization of two production lines in the company Frauenthal Automotive Hustopece Ltd. Thanks to this design, reduction of needed operators can be realized and design is linked with process time analyzation. Also a new design of working tools is created, which should help operator and improve ergonomic of workplace. The last part discusses about implementation costs of new design.

This thesis is dealing with the issue of risk management during order processing in manufacturing company, which is focused on textile production. Introduction of thesis is presenting theroretical basis. Practical part of the thesis is dealing with company introduction organizational structure of the body, product range, order progressing, OSH policy and environmental policy. Tools chosen for risk assessment techniques - analysis of the causes and consequences (Ishikawa diagram), analysis of possible errors and their consequences (FMEA) and the Pareto chart. The thesis aims to analyze the risks and for the most significant risks to process proposals for their elimination.

The thesis deals with production planning. It contains theoretical description of methods used for production planning and optimizing. Thesis describes bottleneck problems in production. It offers overview of ways to identify and analyze bottleneck influence to manufacturing process efficiency. Thesis proposes ways to eliminate bottlenecks using various algorithm types. It applies theoretical knowledges from optimization and graph theory to program creation that is focused on order delay and readjustment time minimizing. The program implements genetic algorithm.

An important consideration in discrete event dynamic systems control theory is the selection of a suitable modeling formalism that can capture the complex characteristics of the system and the capability to automatically synthesize a controller based on the system model. Net condition event systems are well suited for modeling complex discrete event dynamic systems owing to their input and output structure, which effectively captures the behavior of the physical devices to be monitored and/or controlled. To date, net condition event systems control models have not been extensively applied to highly automated manufacturing systems and there are few guidelines on how to automatically generate Programmable Logic Controller programming languages from net condition event systems models. This research automatically converted net condition event systems control models into Programmable Logic Controller programming language and evaluated the applicability of the proposed methodology in highly automated manufacturing systems using HAS-200 as a test bed.

The aim of this diploma thesis is the practical implementation of lean manufactur-ing elements according to the lean methodology in an engineering company engaged in job production in order to reduce waste and increase production efficiency. At the beginning of the thesis is a presentation of a company that manufactures steam turbines. The following is a short chapter on the background of lean manufactur-ing, focusing on the Kaizen philosophy. The main focus of this thesis is on 3 projects of a practical demonstration of the application of lean manufacturing. The aims are to re-duce waste, streamline production and other individual goals. Each project contains an introduction to the problem, setting its goals, performing a root cause analysis with pro-posing measures to meet the project objectives. The evaluation of the project contains both the achieved benefits as well as the limitations of the provided solution. At the end of this work is an overall evaluation of the financial benefits and costs of individual projects.

The global market is very competitive due to fast changes in complex business environments and to survive or expand the business, organizations must embrace organizational change. However, adapting to change is not always easy, where organizations may experience obstacles and resistance along the way. Organizations may also experience that it is very hard to implement lean successfully, due to lack of know-how but especially resistance. The traditional way is to blame the blue-collars for the disturbing circumstances but in modern times the wind has changed its course where the managers themselves can be a contributor for implementation failures. Therefore, the aim of the research is to investigate what advantages that can be obtained by implementing a certain change initiative. Furthermore, to determine where resistance occurs and how to eliminate or reduce them. The change initiative in this research is implemented by conducting a case study in a Small Medium Enterprise (SMEs), where the main goal is to reduce the changeover time of a machine, by finding improvement suggestions using the Single Minute Exchange of Die (SMED) methodology. The results generated several improvement opportunities and gave an indication that there is a huge potential for improvements and elimination of waste during a typical changeover. The positive outcomes of implementing these improvement opportunities could theoretically reduce the changeover time, which directly reduces the overall cost but higher responsiveness, flexibility and efficiency can also be obtained. However, the evidence tells a story where the organization could experience obstacles during the implementation of the improvement suggestions, due to several factors. Surprisingly, the evidence points out that one root problem for resistance is difficulties of describing the underlying reason of the change initiative to the blue-collars. Moreover, there is in fact resistance and lack of awareness of the SMED methodology among the blue-collars and the managers, where fear of the unknown is another root problem for resistance.

This thesis deals with the current state of assembly workplace for prefabrication in selected company. Using lean manufacturing principles it describes and subsequently eliminating all forms of waste that occur in the workplace. Part of the project is to design a new layout of the manufacturing cell, operation balancing and standardize the work of operators in the process. The project aims to achieve the planned production volumes at the same or lower operating costs.

The aim of this diploma thesis is detail description of theory, design process and final realization of single-purpose machine for pressing canister funnels. Theoretical section of this work covers manufacturing standards of the electrical cabinets, options for the single-purpose machine control with focus on the programmable logic controller e.g. PLC, PLC control program concept with definition of the main alarm states and description of two types of electrical cabinet. Practical part contains description of the electrical cabinet, its block diagram, photo documentation of the wiring (chapter 4.), chosen PLC type, its advantages and detail program description using Ladder diagram notation, communication with operator realized with touch LCD panel, programming environment for this LCD panel and program realization process. Finalized machine description and its photo documentation in manufacturing process is covered in the end. This diploma thesis is based and extends previously successfully defended semester project.

The design approach changed in the last decades with the innovation offered by software for Computer-Aided Design (CAD), three-dimensional computer modelling and digital fabrication methods enabling new forms. The development in digital fabrication techniques led to the application of automatic processes in the structural engineering sector through Additive Manufacturing (AM) based technologies. It offers numerous benefits over conventional manufacturing methods, such as design of more complex and optimized components due to greater freedoms in shape and geometry, therefore bringing to a reduced material usage and shortened build times. The focus of this research is on the metal additive manufacturing methods, in particular, the adopted technique is the Wire-and-Arc Additive Manufacturing (WAAM), which best suits the possibility to realize large-scale metal structures and to allow new geometric forms. WAAM advantages compared to the other processes are fast large-scale production, freedoms in shape and geometry, structural efficiency with reduced material usage. The current research comprises the overarching process from the computational design to the mechanical characterization of the WAAM-produced elements, through the fabrication step. The computational design and fabrication stages were carried out at Technische Universität Braunschweig. There is still limited research focused on the characterization of WAAM-produced metal elements for structural engineering applications, therefore the research carried out at University of Bologna was focused on the establishment of 3D-outcome mechanical properties, pointing up the influence of surface roughness and imperfections on the mechanical response, together with the study on how the intersection between WAAM-produced bars influences the overall behavior of the specimen.

Magister Commercii - MCom
This research project focuses on the application of process improvement techniques in a clothing manufacturer to address delay problems in workflow in the factory. The objective of the research is threefold; investigate delays at the beginning of production and make suggestions, show the usefulness of continuous improvement techniques in improving activities in a clothing manufacturer and demonstrate how action research can be used in doing research in production and operation management. Using tools such as flow charts, check sheets, pareto analysis, fishbone diagrams, interviews and the "ask why five times" tool, an investigation into delays led to a second investigation into sewing defects. This established that these sewing defects are caused mainly by time constraints, the malfunctioning of machines, the wrong handling of garments, and previous operations. After an investigation using the above tools it was established that these defects could be addressed by setting realistic targets, doing regular maintenance on machines, cautioning operators to be more careful during their operations, and encouraging regular checks on garments before the next operation. The action learning methodology led to the following lessons; selecting a correct measuring tool is important, that not all tools need to be used, and that it takes time to do a research project using this method.

Mestrado em Engenharia e Gestão Industrial
As ferramentas lean auxiliam a aplicação dos conceitos lean levando à redução dos desperdícios ao longo da cadeia de valor e redução do lead time. Este projeto tem como objetivos melhorar o processo de picking de materiais e a redução do WIP ao longo do fluxo de materiais da empresa 4Lean de forma a melhorar o fluxo de materiais. Para atingir esses objetivos foi feito uma pesquisa de artigos científicos e literatura existente. Depois analisaram-se os processos de forma a se conseguir identificar melhorias futuras. Com este projeto conseguiu-se alcançar poupanças na área responsável pelo processo de picking com a implementação de supermercados, estruturas de organização de paletes e novo modelo de carro de picking. Devido a mudanças de layout e melhorias nos processos foi possível reduzir o WIP e aumentar a capacidade em 70%.
Lean tools support the application of the lean concepts leading to reduce the waste through the supply chain and reducing lead time. This project aims to improve the picking materials process and reduction of WIP along the materials flow on the company 4Lean in order to improve the material flow. To achieve these objectives has been done a research of scientific papers and literature. Then the processes were analyzed in order to identify future improvements. With this work we able to achieve savings on the area responsible for the picking process with implementation of supermarkets, structures to organize pallets and new model car of picking. As result of the layout changes and improvements on the processes was possible to reduce the WIP and increase the capacity by 70%.

Dissertação de Mestrado em Matemática apresentada à Faculdade de Ciências e Tecnologia
O desenvolvimento de novas tecnologias em diferentes áreas da ciência tem impulsionado e mudado profundamente o modo de ser e estar no mundo industrial. Estas tecnologias, a globalização e a procura expõem a indústria a um mercado muito competitivo. Os clientes são cada vez mais seletivos e exigentes, um fato que leva a indústria a investir seriamente em tecnologias de ponta com o objetivo de ser mais eficiente, economicamente sustentável e satisfazer os seus clientes. Neste contexto, a indústria de moldes começou a investir em tecnologias, tais como, a tecnologia SLM (Selective Laser Melting) ou Fusão seletiva a laser. Fusão seletiva a laser, que é baseada no princípio de fabricação de objetos por adição sucessiva do material, é reconhecida como uma tecnologia de fabrico muito promissora. Esta tecnologia é adequada para o fabrico de objetos com elevada complexidade geométrica que seria impossível por outras formas. Esta tecnologia tem um ponto fraco relacionado com o acabamento superficial, portanto, há uma necessidade de fresar-se o objeto para a remoção do excesso do material ou seja a rugosidade. Para o efeito e com o objetivo de otimizar as sucessivas fases aditivas e subtrativas, propusemos o uso do eixo médio e suas extensões como uma forma prática de resolver o problema e obter um ótimo acabamento superficial. A noção do eixo médio está relacionada com a teoria dos diagramas de Voronoi e já foi proposto em diversos processos de fresagem. É neste contexto que precisamos encontrar a melhor técnica que melhor se adequa à nossa situação para determinar exata ou aproximadamente o eixo médio.
The emergence of new technologies in different scientific areas has been boosting and deeply changing the industrial world. Globalization and associated demand have been exposing the industry to a very competitive market. The clients are increasingly demanding and selective, which compels the industry to seriously investing in high-end technologies in order to be more efficient, economically sustainable and to be able to satisfy its clients. In recent years the mould industry has been investing in new technologies, such as Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), Electron Beam Melting (EBM), Selective Laser Melting (SLM).Their differences are essentially in mechanical details. Selective laser melting, which is based on the principle of material incremental manufacturing, has been recognised as a promising additive manufacturing technology. The technology is suited for creating geometrically complex components that can not possibly or feasibly be made by any other means. Since this technique has a weak point related to the surface finishing, there is a need to use techniques such as milling to remove the surplus material. To plan and optimize the successive additive and subtractive phases, we propose to use the medial axis and certain extensions of it, as a practical way of determining the best possible finishing quality of the produced object. The notion of medial axis is closely related to the theory of Voronoi diagrams, and has been proposed in several milling applications that involve motion planning. To that end we have to find which of the available construction strategies best suits our needs to determine exactly or approximately the medial axis.
Outro - This work is co-financed by the project HEST of Institudo de Bolsas de Moçam- bique and by the project PT2020-POCI-SII& DT 3414: additive.MILLING - Add Milling to Additive Manufacturing. Co-financed by FEDER (Fundo Europeu de Desenvolvimento Regional), in the scope of the Program Portugal 2020, through COMPETE 2020 (Programa Operacional Competitividade e Internacionalização)

Dissertação de mestrado integrado em Engenharia e Gestão Industrial
O presente projeto de dissertação, realizado no âmbito do Mestrado Integrado em Engenharia e Gestão Industrial, foi desenvolvido em contexto industrial na empresa AptivPort Services S.A, em Braga. Esta organização, inserida no ramo da indústria automóvel e dedicada à produção de componentes plásticos e eletrónicos para o fabrico de sistemas de navegação, controlo e infotainment, procura agora, através do seu programa Lean 2.0, adotar um conjunto de ferramentas e metodologias lean que permitam a eliminação de desperdícios, redução de custos e aumento de qualidade do seu sistema produtivo. O principal objetivo deste projeto consiste em analisar, diagnosticar e melhorar, com recurso a um conjunto de ferramentas e metodologias lean, o desempenho do sistema produtivo de um dado “produto A”, com principal foco nas métricas de Work in Process (WIP), lead time, produtividade e qualidade. Em primeiro lugar, realizou-se a revisão da literatura em torno da filosofia Lean Manufacturing, nomeadamente ao nível das bases que suportam esta filosofia e a algumas das principais ferramentas e metodologias que serviram de base teórica para o desenvolvimento do projeto. Seguidamente, e tendo por base a metodologia de investigação action-research, efetuou-se a análise e diagnóstico da fase inicial do processo produtivo em questão, fazendo uso de ferramentas como o estudo de tempos, análise ABC, Value Stream Mapping (VSM), e diagrama de spaghetti. Assim, através destas, foi possível identificar um conjunto de problemas como a falta de capacidade produtiva; o excesso de WIP em determinados setores da produção; a elevada incidência do modo de falha – “No Trouble Found” (NTF); a elevada quantidade de ações de transporte e movimentação; e ainda, algumas insuficiências relacionadas com o sistema de gestão visual da fábrica e com o indicador de desempenho chave – Overall Equipment Effectiveness (OEE). Por fim, através da implementação de propostas de melhoria como o aumento da capacidade produtiva, a implementação de um novo sistema de transportes e a criação de um plano de reação standard e de um standard de gestão visual, foi possível obter uma redução da quantidade de WIP presente no sistema produtivo em questão de cerca de 10,5% (100 759 € de capital parado); uma redução do lead time de cada uma das placas eletrónicas afetas ao “produto A” de cerca de 4,68 horas e 1,15 horas, cada; um aumento de produtividade de cerca de 7,8%; e ainda, algumas melhorias de qualidade não quantificadas. Em suma, tudo isto terá resultado numa poupança monetária anual de cerca de 46 143 €/ano.
The present dissertation project, carried out under the Integrated Master's Degree in Industrial Engineering and Management, was developed in an industrial context at AptivPort Services S.A, in Braga. This organization, inserted in the field of the automotive industry and dedicated to the production of plastic and electronic components for the manufacture of navigation, control, and infotainment systems, is now seeking, through its Lean 2.0 program, to adopt a set of lean tools and methodologies, that allow for the elimination of waste, cost reduction and increase in quality of its own production system. The main purpose of this project is to analyze, diagnose and improve, using a set of lean tools and methodologies, the performance of the production system of a given “product A”, focusing mainly on the Work in Process (WIP), lead time, productivity and quality metrics. First, a literature review was carried out on the Lean Manufacturing philosophy, namely, on the bases that support this philosophy, and on some of the main tools and methodologies that served as a theoretical basis for the development of the project. Then, based on the action-research methodology, an analysis and diagnosis of the initial phase of the production system in study was carried out, using tools such as time study, ABC analysis, Value Stream Mapping (VSM), and the spaghetti diagram. Thus, with these, it was possible to identify a set of problems such as the lack of productive capacity; the excess of WIP in certain sectors of production; the high incidence of the failure mode – “No Trouble Found” (NTF); the high amount of transport and motion actions; and also, some insufficiencies related with the plant’s visual management system and with the Overall Equipment Effectiveness (OEE) key performance indicator. Finally, through the implementation of improvement proposals such as the increase in production capacity, the implementation of a new transport system and the creation of a standard reaction plan and a visual management standard, it was possible to obtain a reduction in the amount of WIP present in the studied production system of approximately 10,5% (the equivalent of 100 759 € of idle capital); a reduction in the lead time of each one of the electronic boards linked to “product A” of around 4,68 hours and 1,15 hours, each; an increase in productivity of about 7,8%; and also, some unquantified quality improvements. In short, all this resulted in an annual saving of 46 143 €/year.

Dissertação de mestrado integrado em Engenharia e Gestão Industrial
A presente dissertação descreve um projeto de melhoria de um processo produtivo de uma empresa da indústria automóvel. Este projeto desenvolvido em ambiente industrial insere-se no último ano do Mestrado Integrado em Engenharia e Gestão Industrial para conclusão do curso. O projeto foi desenvolvido na Continental Mabor, devido à necessidade da empresa analisar um processo produtivo que gera uma elevada quantidade de material não conforme que pode ser reaproveitado. Como tal, o projeto consistiu em reduzir este desperdício e procurar que seja reutilizado nas melhores condições. O principal objetivo consiste na análise da situação e no desenvolvimento de propostas de melhoria para aumentar a produtividade do processo de extrusão de pisos. Aplicando o Lean Six Sigma (LSS), conseguiu-se identificar as variáveis que influenciam a qualidade da produção de pisos através de várias técnicas e ferramentas que as filosofias Lean Manufacturing e Six Sigma dispõem e que são a base do LSS. Recorrendo ao ciclo DMAIC (Define, Measure, Analyze, Improve, Control), percorre-se fases para a compreensão e resolução do problema. Nas diferentes fases, executam-se técnicas e ferramentas associadas ao Lean Manufacturing e Six Sigma permitindo uma análise estruturada de diferentes causas que influenciam negativamente o processo de extrusão e consequentemente a identificação de várias oportunidades de melhoria. A quantidade de propostas de melhoria implementadas permite considerar que o projeto foi um sucesso. Os objetivos da dissertação foram atingidos, visto que a quantidade de material não conforme criado durante o processo de extrusão de pisos foi reduzida. Os custos com a qualidade diminuíram e a produtividade aumentou.
This thesis describes a project to improve a productive process of a company from the automotive industry. This project developed in an industrial environment is part of the final year of the Master in Industrial Engineering and Management for course completion. The project was developed in Continental Mabor, which has a production process that generates a quantity of nonconforming material that can be reused. As such, the project was to reduce this waste and seek to be reused in the best conditions. The main objective consists to analyze the situation and the development of proposals for improvement to enhance the proper functioning of the extrusion process. Applying Lean Six Sigma (LSS), the identification the variables that influence the quality of the production treads was obtained through various techniques and tools that philosophies Lean Manufacturing and Six Sigma have and which are the basis of the LSS. Using the DMAIC cycle (Define, Measure, Analyze, Improve, Control), runs up phases for understanding and resolve the problem. In different phases, executing techniques and tools associated with Lean Manufacturing and Six Sigma allowing structured analysis and different causes that negatively influence the extrusion process and hence the identification of several opportunities for improvement. The amount of improvement proposals implemented suggests that the project was a success. The costs were reduced to quality and productivity increased, since the amount rejected of tread decreased.

Dissertação de mestrado em Engenharia Industrial
A presente dissertação retrata a implementação de ferramentas de Lean Manufacturing em ambiente industrial, mais concretamente no sistema produtivo da empresa Flexospuma, Lda., inserida na indústria de componentes para calçado. Os objetivos desta dissertação são reduzir em 20% o tempo gasto em atividades que não acrescentam valor no setor da produção e reduzir erros do planeamento e da produção em 50% até 30 de Junho de 2015. Este projeto iniciou-se com uma revisão literária exaustiva na área de Lean Manufacturing no sentido de se aprofundar conhecimentos sobre esta temática e sobre quais as ferramentas que poderiam ser utilizadas ao longo do trabalho. Já no shoop floor foi feita uma recolha de informações no sentido de se perceber o funcionamento da área produtiva da empresa e posteriormente foi efetuado um diagnóstico ao sistema produtivo da mesma utilizando ferramentas como o VSM, o diagrama de Spaghetti, um registo de observações às atividades desenvolvidas na produção e uma análise de erros ao planeamento e à produção. Deste diagnóstico surgiram algumas propostas de melhoria, especificamente uma reorganização do layout, a instalação de um software de procura de cortantes, a criação de um armazém de matéria-prima, a implementação de um novo sistema para eliminação de restos de materiais, a aplicação de 5S numa bancada de ferramentas, rotulagem das estantes e gestão visual nas estantes de cortantes. Os colaboradores da zona administrativa tomaram também a iniciativa de efetuar algumas melhorias à sua área, nomeadamente na organização de dossiers, no número de vias utilizadas nos documentos e na criação de um manual de procedimentos. Como resultado, foi possível reduzir os desperdícios no setor da produção em 38,60% e foi também possível reduzir o número de erros que se verificavam na produção e no planeamento em 85,71%.
The present dissertation portrays the implementation of Lean Manufacturing tools in industrial environment, more specifically in the production line of the company Flexospuma, Lda, inserted in the footwear components industry. The goals of this dissertation are to reduce in 20% the time spent in activities that don’t add value to the production process and also reduce planning and production errors in 50% until June 30, 2015. This project began with a thorough literature review in the area of Lean Manufacturing in an effort to deepen the knowledge on this subject and learn which tools could be employed throughout the work. Already in the shoop floor a collection of information was made in order to understand the functioning of the company’s production line, followed by a diagnosis of the same production line using tools like VSM, Spaghetti diagram, an event log and error analysis. From the diagnostic some improvement proposals emerged, specifically, a reorganization of the layout, improvements such as the implementation of search engine software designed to search cutting molds, the creation of a storage area for raw materials, the implementation of a new system for the disposal of leftover materials, application of 5S in the tool shelf, labeling of shelves, and visual management in the cutting molds shelfs. Employees of the administrative area also took the initiative to make some improvements to their area, namely, in file organization, in the number of copies used per document and in the creation of a procedure manual. As a result, it was possible to reduce waste in the production line in 38,60% and was also possible to reduce the number of errors detected in production and planning in 85,71%.

This dissertation reports the investigation and combination of optimization methodologies and the result of implementing them within a production environment. A literature survey was conducted on the optimization methodologies Lean Manufacturing and theory of constraints (TOC). A number of production optimization methodologies were studied and considered for application to the case study organisation. Due to the small size and relative simplicity of the operation, these methodologies had to be simplified and combined into a more relevant form. A refractory manufacturer was used as a case study for the investigation into the optimization of the dry batch plant. Lean Manufacturing and TOC are optimization methodologies that could be employed to optimize the dry batch plant. Tools from these methodologies were used to investigate problems identified within the production process that were causing the batching plant to perform non-optimally. A time and motion study was conducted and a process flow chart was created to understand the production process. Wasteful activities were identified using a value stream map and a flow process chart was used to visualise the movement within the production process. A 5-Why analysis was conducted to determine the root causes. An optimization plan was created to eliminate the wasteful activities and the operational measures, that is throughput, inventory and operating expense, were used as to determine what the effect the optimization plan would have on the wasteful activities (Lean Manufacturing) found within the batching plant and the organisation. The results of the combined effect of the optimization plan are discussed focusing on the improvements in the operational measures and the increase in profit from sales. Future research is suggested to improve the benchmarking of the optimization plan and any future improvements that the organisation might implement.
MSc (Development and Management Engineering), North-West University, Potchefstroom Campus, 2015

The topic of my dissertation is "Organization and management of production in selected enterprise". The main goal of this dissertation is mapping of selected enterprise in one year period and obtain sufficient amount of information for future analysis and suggest possible improvements. The identification data, characteristic, products and services and production planning of selected enterprise are provided in introduction of practical part of this dissertation. Analysis of present state with mapping of present state for individually semi-finished products is introduced in the next part of dissertation. For analysis of present state was calculated VA index and for each semi-finished product was created diagram of material movement in next chapter. The goal of analyses and diagram is the finding of narrow spaces in the material flow. The target map of future state was created in the next part. This map is based on present map. The future map presents critical factors that need to be improved. Finally it defines a new VA index, which should be approach to the current state. The penultimate section includes recommendations methods and elements of lean production to the new production hall which the company wants to build. Among the recommended methods are mainly the 5S method, visualization, standardization, SMED and Bottleneck. The last chapter contains a number of measures. For example employee motivation, continuous improvement, personal responsibility, introduction of EDI and ergonomics which would lead to the improvement of the business this enterprise.

When the nonconformities are independent, a multivariate control chart for nonconformities called a demerit control chart using a distribution approximation technique called an Edgeworth Expansion, is proposed. For a demerit control chart, an exact control limit can be obtained in special cases, but not in general. A proposed demerit control chart uses an Edgeworth Expansion to approximate the distribution of the demerit statistic and to compute the demerit control limits. A simulation study shows that the proposed method yields reasonably accurate results in determining the distribution of the demerit statistic and hence the control limits, even for small sample sizes. The simulation also shows that the performances of the demerit control chart constructed using the proposed method is very close to the advertised for all sample sizes. Since the demerit control chart statistic is a weighted sum of the nonconformities, naturally the performance of the demerit control chart will depend on the weights assigned to the nonconformities. The method of how to select weights that give the best performance for the demerit control chart has not yet been addressed in the literature. A methodology is proposed to select the weights for a one-sided demerit control chart with and upper control limit using an asymptotic technique. The asymptotic technique does not restrict the nature of the types and classification scheme for the nonconformities and provides an optimal and explicit solution for the weights. In the case presented so far, we assumed that the nonconformities are independent. When the nonconformities are correlated, a multivariate Poisson lognormal probability distribution is used to model the nonconformities. This distribution is able to model both positive and negative correlations among the nonconformities. A different type of multivariate control chart for correlated nonconformities is proposed. The proposed control chart can be applied to nonconformities that have any multivariate distributions whether they be discrete or continuous or something that has characteristics of both, e.g., non-Poisson correlated random variables. The proposed method evaluates the deviation of the observed sample means from pre-defined targets in terms of the density function value of the sample means. The distribution of the control chart test statistic is derived using an approximation technique called a multivariate Edgeworth expansion. For small sample sizes, results show that the proposed control chart is robust to inaccuracies in assumptions about the distribution of the correlated nonconformities.
Graduation date: 2004

A empresa Japonesa Toyota foi pioneira na descoberta de uma nova forma de gestão com o desenvolvimento do Sistema Toyota de Produção (Toyota Production System,TPS) Este sistema integra princípios da filosofia “Lean Manufacturing (LM)” utilizando os métodos “Just-in-time”, “Kanban” e “Heijunka”. É notória a diferença na capacidade competitiva das empresas, o que se deve a diferenças a nível organizacional e, ainda, à correta adaptação das ferramentas LM à atividade da empresa. O princípio LM pode ajudar empresas menos organizadas, considerando que as dificuldades nas aplicações de práticas Lean se devem principalmente a três fatores: i) falta de comprometimento, ii) falta de colaboradores qualificados e iii) a ambientes de produção intermitentes. Com esta dissertação pretende-se recorrer ao estado atual da arte no que diz respeito a implementações de LM. Esta revisão bibliográfica permitiu recolher informações e métodos necessários para iniciar a proposta de implementação de práticas Lean a processos de resposta rápida de assistências de manutenção em estrada da Empresa T. Elaborou-se a abordagem ao problema desenvolvendo uma ferramenta de suporte à implementação LM. Esta éconstituída pela análise de Pareto, diagrama de esparguete, VSM do estado atual, VSM do estado futuro, análise do produto, meios aplicar, e aplicar estado futuro. O estudo foi aplicado a um veículo da Empresa T destinado a assistências em estrada, e como ponto de partida estudou-se um produto concorrente com mais valor. Apresenta-se a proposta para o caso prático com desenhos assistidos por computador e descrevem-se as melhorias perpectivadas. Este estudo pretende lançar e iniciar melhorias contínuas através de eventos kaizen de forma a envolver os colaboradores da instituição, beneficiar com o conhecimento adquirido e, ainda, motivar a equipa para a esperada constante melhoria.
The Japanese company Toyota was pioneered in the application of a new form of management, through the development of the Toyota Production System (Toyota Production System, TPS). This system integrates principles of the "Lean Manufacturing” (LM) philosophy, using the methods "Just-in-time", "Kanban" and "Heijunka". These findings emphasize the differentiation verified in the competitive capacity of the enterprises, which is due to differences at the organizational level and proper adaptation of LM tools to the activity of the company. The LM may help the neediest companies organizationally, and considers that the difficulties in the application of Lean practices, are due mainly to three factors: lack of commitment, reduce of qualified employees and intermittent production environments. In this thesis, we intended to analyze the current state of the art in what concern to methods of LM. This literature review helped to start our proposal, which consists in the implementation of the Lean practices to rapid response cases in the assistance of vehicle maintenance in road by the T Company. To achieve our proposal, we have elaborated the approach to the problem, developing an implementation support tool LM, consisting of Pareto analysis, spaghetti diagram, VSM current state, VSM future state, product analysis, means to apply, and apply state future. The study was applied to a T Company vehicle involved in the assistance of vehicles in the road, and as a starting point we studied a more competitive product value. We also presented a proposal for the desired improvements using computer aided design technologies. Finally, this study intends to launch and initiate continuous improvement through kaizen events, in order to involve employees of the institution and benefit from the knowledge acquired and also to motivate the team to the expected constant improvement.