Dissertations / Theses on the topic 'One-Piece-Flow'

Mestrado em Engenharia Mecânica
O pensamento lean é cada vez mais visto como uma método a seguir pelas empresas que pretendem tornar-se de uma forma contínua mais competitivas e capazes de responder as necessidades dos seus clientes. Esta filosofia consiste em eliminar todos os desperdícios existentes, entende-se por desperdícios tudo aquilo que se faz sem que acrescente valor ao produto. Esta dissertação teve como base um estágio orientado para o pensamento lean. O objectivo deste estágio é analisar três casos de estudo com o intuito de efectuar o fluxo contínuo entre as diversas operações a que estão sujeitas as peças em cada caso. Obtendo um fluxo contínuo consegue-se eliminar alguns dos desperdícios identificados pelo pensamento lean, tais como, armazenamento de peças em contentores, espaço ocupado por estes, movimentações e transportes desnecessários. Foram analisados três casos de estudo com o intuito de encontrar a melhor solução adaptada à realidade da empresa. Por vezes pequenas alterações no layout de uma empresa podem trazer grandes vantagens logísticas evitando assim o transporte excessivo das peças que se encontram em produção.
The lean thinking is becoming more and more notorious within the companies which want to be continuously more competitive and able to respond the requests from their clients. This method consists in eradicate every kind of waste. Waste is everything which doesn’t add value to the product. This thesis was based on a Lean thinking orientated trainee program. The goal of this program was to analyze three cases of study, with the aim of applying the continuous flow within the several production operations. The obtainment of a continuous flow allows some waste elimination, such as, part storage in containers, occupied space, transactions and unnecessary movements. Three cases of study were analyzed in order to find the best solution towards the company reality. Sometimes small layout changes can bring big logistic benefits, avoiding the excessive transport from parts which are in production.

Thesis (M.S.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 1997, and Thesis (M.S.)--Massachusetts Institute of Technology, Sloan School of Management, 1997.
Includes bibliographical references (p. 69).
by Steven R. Harman.
M.S.

Il progetto centrale a questo elaborato di tesi si basa sull’esperienza di tirocinio presso l’azienda Kelvin S.r.l., specializzata nella progettazione e produzione di condizionatori industriali. L’obiettivo principale è quello di implementare le logiche fondanti la filosofia della Lean Production in ambito produttivo, al fine di apportare miglioramenti in ottica di Continuous Improvement. Questo elaborato tratta in particolare della riprogettazione di una linea di scambiatori di calore, focalizzandosi sullo studio di una particolare famiglia di prodotto. Si è studiato il flusso del valore attraverso una mappatura tramite Value Stream Mapping e si è progettata una soluzione ottimale basata sulla riduzione delle tempistiche di assemblaggio e sul livellamento dei carichi di lavoro, eliminando i pre-assemblati e tutti gli sprechi che ne derivano. È stato attuato un insieme di miglioramenti basati su: applicazione delle 5S, ottimizzazione dell’area di lavoro e modifica delle sequenze di produzione e del metodo di lavoro. La combinazione di tutti questi miglioramenti ha definito un maggiore controllo del processo in termini di sicurezza, qualità ed efficienza, in ottica One-Piece Flow, ottenendo un miglioramento dell’indice di flusso del 10% e la riduzione del tempo di attraversamento del prodotto dal magazzino materie prime al magazzino prodotti finiti del 50%, passando da 4 a 2 giorni.

Il progetto fondato sul Continuous Improvement, all’interno del quale è stata sviluppata l’esperienza di tirocinio presso l’azienda inglese Celli UK di proprietà del gruppo italiano Celli S.p.a., vede come obiettivo principale quello di implementare ed attuare le tecniche sulle quali si basa la filosofia della Lean Manufacturing, con il fine ultimo di apportare miglioramenti tangibili attinenti al reparto produttivo e misurarne i risultati. L’elaborato della tesi è incentrato sulla riprogettazione ed ingegnerizzazione di una linea di assemblaggio di un particolare modello di spillatrice di birra (DM3), ritenuta critica per l’efficienza globale del reparto produttivo. Inoltre, viene illustrato come vengono messi in pratica strumenti Lean in relazione alla stessa linea target. I risultati ottenuti sono stati misurati tramite determinati KPI relativi alla riduzione del Tempo Ciclo di assemblaggio, all’efficienza della linea ed alla riduzione di pre-assemblaggi. È stato inoltre calcolato il cut-off period dell’investimento che è stato necessario tramite il payback. Oltre a ciò, durante il periodo di tirocinio, è stato implementato un nuovo sistema gestionale per il quale è servito migrare tutti i dati inerenti ai prodotti, le distinte base e le route dal gestionale obsoleto al più recente software ERP Microsoft Dynamics. Successivamente è proseguito il lavoro di creazione degli stessi per i nuovi prodotti acquistati e/o venduti.

Globalization and the increasing time to market have led to ever-higher requirements on the production systems. More than often the short-term thinking and the chase for profit lead to cheap quick fixes. The manufacturing industry changes slowly while the market is changing rapidly, which requires long-term planning for capacity increase but at the same time the ability to rapidly respond to changes. The most crucial factors determining the ability to efficiently produce and deliver a product to market is the utilized production system and a well stated manufacturing strategy. The choice of a certain production system depends on company conditions and requirements as well as the market demands. The current production systems performance and ability to handle different production volumes and divergence must be considered and evaluated from an economical perspective. During this thesis work the benefits and disadvantages with batch flow and one-piece flow have been examined. Generally one-piece flow had been considered the most efficient regarding performance and economical aspects. Meanwhile, batch flow had some benefits associated to it regarding high level of flexibility to handle several different product variants and better possibilities to govern the material flow compared to one-piece flow. There has also been examined which are the most crucial factors affecting the choice between one-piece flow and batch flow. It emerged during the thesis work that the most crucial factor affecting the choice of production system was the Manufacturing Strategy. It can be considered as the ground for every decision regarding the production system and future investments. It determines where the company currently stands, where they want to be in the future and which steps they need to take to get there. The economical factor is as least as important because all decisions include more or less costly investments. At the same time the chosen production system must be as efficient as possible and generate money for the company. Based on these two main factors other interesting factors have been presented. These factors may not affect the choice as much, but are to be considered as important in this context The most crucial factors found to affect the choice of a production system were; Manufacturing Strategy, Economical factors, Production planning and control, Flexibility and capacity, Production volume, variants and trends. The research work has been conducted over a twenty-week period, during which data collection has been performed via Multiple Case Studies at four companies manufacturing similar components within the light and heavy automotive industry. Additional data collection has been performed through a literature review by examining relevant material for the research questions. This have led to a collected knowledge base regarding benefits and disadvantages with each production system along with underlying reasons for deciding on one of them. Based on the collected material from the Case Studies and the theoretical findings, a Mind map visualizing the crucial factors affecting the choice of a production system is presented. This can be utilized by the companies in order for structured evaluation of their current production system and for planning for future changes within production.
Globaliseringen och den ökande pressen på företag att producera och få ut produkter på marknaden på kortast möjliga tid har lett till att det ställs allt högre krav på produktionssystemen. Allför ofta leder kortsiktigt tänkande och jakten på vinster till att företag väljer enkla och billiga snabblösningar. Tillverkningsindustrin förändras långsamt medans marknaden ändras fort, vilket kräver att företagen kan planera för långsiktiga kapacitetsökningar och ändå ha beredskap för att snabbt kunna anpassa sig till förändringar. Det som till allra största del avgör hur effektivt man kan producera och leverera en produkt till marknaden är vilket produktionssystem ett företag använder samt en välformulerad tillverkningsstrategi. Vilket produktionssystem man väljer är beroende av vilka förutsättningar och krav ett företag har lika mycket som av marknadskraven. Man måste ta hänsyn till det nuvarande produktionssystemets prestanda och möjlighet att hantera ändrade produktionsvolymer och variantflora och utvärdera detta ur en ekonomisk synvinkel. Under detta examensarbete har för- och nackdelar med batchflöde och enstycksflöde undersökts och utvärderats. Generellt sätt har enstycksflöde konstaterats vara mest effektivt rent ekonomiskt och prestandamässigt. Däremot, har batchflöde tilldelats fördelar som hög flexibilitet att hantera olika produktvarianter och bättre möjligheter att styra materialflödet jämfört med enstycksflöde. Det har även undersökts vilka som är de mest avgörande faktorerna som styr valet av enstycksflöde eller batchflöde. Under arbetets gång framkom det att den mest avgörande faktorn som påverkar valet av produktionssystem var företagets Produktionsstrategi. Den kan anses vara grunden för alla beslut rörande produktionssystemet och framtida satsningar. Där visar man var företaget befinner sig idag samt var man vill vara i framtiden och vilka beslut man måste ta för att ta sig dit. Den ekonomiska faktorn är minst lika viktig, då alla beslut i slutändan handlar om mer eller mindre kostsamma investeringar. Samtidigt måste det valda produktionssystemet vara så effektivt som möjligt och generera pengar till företaget. Med utgångspunkt från dessa två huvudfaktorer har andra intressanta faktorer tagits fram, som inte påverkar valet av produktionssystem i lika hög grad, men som ändå kan anses vara viktiga i sammanhanget. Forskningsarbetet har bedrivits under 20 veckors tid, där datainsamling har utförts via fallstudier på fyra företag som tillverkar liknande komponenter inom fordonsindustrin. Vidare datainsamling har gjorts genom en litteraturstudie där relevant material för forskningsfrågorna har undersökts. Detta har lett till en samlad kunskapsbas gällande för- och nackdelar med de respektive produktionssystemen samt bakomliggande orsaker till att välja något av dessa produktionssystem. Utifrån det samlade materialet från fallstudierna samt de teoretiska rönen har sedan en tankekarta tagits fram, som visualiserar de avgörande faktorerna som påverkar valet av ett produktionssystem. Denna tankekarta kan företag använda sig av för att på ett strukturerat sätt utvärdera nuvarande produktionssystemet samt planera för framtida förändringar inom produktionen.

This thesis is primary focused on optimization of the production process in a selected company.Teoretical part of this thesis is the result of literature research of Lean Six Sigma, which is mostly used by the company. It is a brief insight to an issue and introduction of the most often used tools from Lean Six Sigma methodology, which were used afterwards in practical part of this thesis. Also there is an introduction of the company and its production portfolio. Crucial part of this thesis is it‘s practical part focused on improving of current situation on the production line with an economical and technical assessment. The main goal was to create more compact and smaller area of product line with lower work in progress.

The subject of this diploma thesis is to improve the manufacturing of ISO standard valves using basic Lean manufacturing methods. Focus was at two levels, the macro level dealing with auxiliary processes for the whole manufacturing area and the micro level looking at removal of waste in the processes on one particular production cell.

This master’s thesis solves the lean production’s methods implementation in the steps assembly department at the company IFE CR, a. s. The first part of the thesis describes the material and information flows and the most serious problems are identified in this part. On the basis of the analysis the optimized future state is designed and possible proposals of solutions are recommended to do for achieving this state. The solution of implementation of a new steps assembly line is solved in detail in the last part.

Tendency of this diploma thesis is to find cost of economies through the device of lean production. On the basis of more than fourmonth monitoring and classification was specificated the problem, which is solved by implementation devices of lean production. Thanks these devices would be cut the bussines costs and salary and helps to do One piece flow too.

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.

碩士
國立中央大學
工業管理研究所碩士在職專班
96
Just like electricity and water, gas raw material plays the key and significant role in semiconductor producer, thin-film transistor liquid crystal display manufacturers and solar industries. Generally speaking, most of the local electronic gases companies basically developed their businesses by traditional batch flow. The traditional production is simple and easy to manage, but on the other hand we also could see the weakness of high inventory, slow response timing and long lead time. Therefore, gradually, Batch flow couldn''t satisfy the Electronic Industry on the requirements of varieties and quick response. Therefore, my study tries to compare the batch flow with one-piece flow by one key point from the production of gas cylinders. Besides, to observe the difficulties and challenges of improving the cylinders package inspection process by inputting the one-piece flow from the case study will be my main research part, and then try to find the possible solutions to make the production more efficiently. The purpose is to find the right production pattern which works perfectly with the end suppliers and reach the target of quick response, zero inventories and no defect. My study figure out the One-piece Flow also could be applicable to the production of gases cylinders in some parts. To earn the biggest profit from the One-piece Flow, the cylinders’ automatic distribution should be improved.

碩士
國立高雄第一科技大學
系統資訊與控制研究所
96
There is a very important character in the process of color filter manufacturing—inspection sampling in process . Inspection sampling will make the product leave the main process and return the main process when the inspection is finished. Such a leave-return inspection sampling process will significantly reduce the productivity and increase the waiting time. To achieve high efficient material flow in such an inspection sampling intensive manufacturing, the production line deployment and material flow layout as well as the execution control of the whole system are the foundamental challenges to be conquered. Facing the above-mentioned issue, the objective of this research is to propose a plant layout including the deployment of the production lines and material flow facilities such that the color filter manufacturing process can be executed piece by piece not only in each production line but also for the entire inspection process. Such a plant layout design is different from the traditional one that inspection sampling can be executed only in batch. For the execution control of this proposed plant layout and it’s operation, a newly proposed color petri net, called Dual-Loop General Event-Driven Modular Colored Petri Nets, DLGED-MCPN, was employed to model and specify all the details of the system. With this proposed model, the whole CF manufacturing system and it’s operation with wide variations can be concisely represented.

碩士
東海大學
工業工程與經營資訊學系
102
To be able to survive in a global competitive environment and meet customer’s expectation in the progress of information technology, the company use Low-Volume-High-Mix (LVHM) model rather than High-Volume-Low-Mix (HVLM) model. In recent years, there are various manufacturing methods and systems in the industries throughout the world. Of these, many practice lean manufacturing methods. The most effective and influential to all of these methods is the “Toyota Production System” (TPS). Although One-Piece flow is the most concrete outcome in Lean Revolution, it is not easy to achieve the goal. Therefore, this study will use the theoretical and practical perspectives to clarify the technical and organizational characteristics of One-Piece flow production. In this study, we want to propose the theory that development of One-Piece flow, it is based on “Socio-Technical” systems in a continuously changing manufacturing environment. The theory that development of One-Piece flow includes a premise and four phases: "Phase 0 - willing", "Phase 1 - setting standards," "Stage 2 - levelized production", "Stage 3 - to solve the problem "and" stage 4 - to maintain and sophisticated ". Through theoretical analysis backed by my personal observations, it firmly believe that One-Piece flow is the result of is a result of the interaction of social systems and technical systems. Social systems is indispensable in One-Piece flow.

碩士
國立雲林科技大學
工業工程與管理系
107
In the global competition, in addition to the competitive price of products, companies also need to satisfy the various needs of customers. Production of customized goods is the current trend. The production patterns of various industries also tend to be diversified. Now, many companies introduce Toyota Production Systems to improve the production line manufacturing process to achieve cost reduction, fast delivery, and stable quality. This research takes the metal manufacturing industry as the object of discussion, and applies One-Piece-Flow process of Toyota Production Systems mode to the production line. Then using P-Q analysis to select the improvement range, and analyzes it with standardized work chart. Let the production line achieve the effects of low input manpower, low lead time, and low inventory of work in process. Through the empirical results of this study, we can understand the steps of the production line to import a One-Piece-Flow process, analysis methods. As a reference for companies to promote the improvement of production lines in the future.

碩士
國立高雄應用科技大學
工業工程與管理系碩士在職專班
102
Toyota Motor Corp. has experienced several decades to develop a production management system. Through the academia and business community validation, "Toyota production system" has been recognized to be the best solution for the market of the low volume and multiple-types demand. However, most of the successful stories are still in the company having a lot of corporate resources. Under Taiwan's SMEs as the main condition, how should implement Toyota production system in SMEs? What benefits after implemented? And what elements must be prepared before implemented? The case study is based on an enterprise about seventy employees, from batch production management launch Toyota production system in "one-piece-flow model” for process improvement, and explore how to transfer from mass into a small batch production. Through the one-piece-flow process and procedure implementation explores the differences and efficiency improvement by a number of indicators. Finally, interview the participants and collect the feedback and suggestions from one-piece-flow implementation, so that those who are interested in this study as a reference. The result of this study shows that the company is still possible to improve the efficiency after one-piece-flow implemented, even in the passive situation between customers and suppliers. The production lead-time is effectively shortened to 7 days from 26 days, to improve the operation efficiency in production line of 55.2%, to reduce the total product working hours of 19.6%, to improve plant space utilization by 16.7%. In order to implement one-piece-flow well, production equipment maintenance status and production lines across the board for the first time yield are the key elements.