Title Page
ABSTRACT
Contents
CHAPTER 1. INTRODUCTION 15
1. Research Background 15
1.1. General background 15
1.2. Description of the company under study and its products 17
2. Statement of the problem, purpose and scope of the investigation 18
2.1. Statement of the problem 18
2.2. Purpose of the investigation 19
2.3. Scope of the investigation 20
3. Research method and study composition 21
3.1. Research method 21
3.2. Composition of the study 21
CHAPTER 2. LITERATURE REVIEW 24
1. Theoretical background of the Lean model 24
1.1. Definition of Lean Manufacturing (LM) 24
1.2. Types of waste based on Lean manufacturing criteria 25
1.3. Elimination of shrinkage or waste 27
1.4. Performance indicators 29
1.5. Lean Manufacturing (LM) tools 30
1.6. Advantages of implementing Lean Manufacturing 37
1.7. Lean Manufacturing and sustainability 38
1.8. Applicability of Lean manufacturing in SMEs 39
1.9. Latin American companies and the LM trend 40
2. PDCA cycle 40
2.1. Plan 41
2.2. Do 41
2.3. Check 41
2.4. Act 41
2.5. PDCA cycle and its applicability in Small and Medium-sized Enterprises (SME) 42
3. SME 42
3.1. Definition of SME 42
3.2. Basic characteristics of a SME 43
3.3. Main growth limitations 43
4. Integration of Lean Manufacturing and the PDCA cycle 44
5. Simulation 45
5.1. Simulation definition. 45
5.2. Emergence and evolution of simulation 45
5.3. Advantages and disadvantages of simulation 45
5.4. PDCA cycle and simulation in SMEs 46
5.5. Simulation in specialized software: Rockwell ARENA 46
5.6. Modules used in the simulation study 46
6. Establishment of hypotheses 47
CHAPTER 3. METHODOLOGY 49
1. Research model 49
1.1. Flowchart of the methodology 49
1.2. PLAN stage (P) 50
1.3. DO Stage (D) 51
1.4. CHECK stage (C) 54
1.5. ACT Stage (A) 55
2. Data collection and analysis method 55
2.1. Data collection 55
2.2. Analysis method 56
CHAPTER 4. PRESENTATION OF RESULTS AND DISCUSSION 57
1. Determination of product families 57
2. Mapping of the VSM current state 57
2.1. Historical sales data 59
2.2. Processing time 60
2.3. WIP and Waiting Time 62
2.4. Machine uptime 62
2.5. First pass yield (FPY) 63
3. Takt time analysis-Current state 64
4. VSM future state 65
4.1. Establishment and dimensioning of the FIFO lane 68
4.2. Summary of the VSM future state 68
5. Capacity Analysis 69
6. Implementation of SMED 70
6.1. Final classification of internal, external and parallel activities 71
6.2. Comparison of times and improvement percentage 72
7. Simulation of improvement activities in ARENA Software 73
7.1. Distribution Analysis-Input Analyzer 73
7.2. Construction of the simulation model 74
7.3. Verification and validation of the simulation model 75
7.4. Scenario analysis 77
8. Analysis of the simulation model by scenarios 78
8.1. VA Time Analysis 78
8.2. WIP Analysis 80
8.3. Analysis of the Number Out 81
8.4. Statistical analysis of performance indicators 83
9. Verification of the hypotheses 84
CHAPTER 5. CONCLUSIONS AND RECOMMENDATIONS 87
1. Conclusions 87
1.2. Implications 88
1.3. Limitations 89
2. Recommendations 89
2.1. Recommendation regarding the improvement of the current state 89
2.3. Future studies 91
REFERENCES 92
APPENDIXES 98
APPENDIX A. METHODOLOGY 98
APPENDIX B. PRODUCT FAMILY MATRIX 99
APPENDIX C. VSM IMPLEMENTATION 100
APPENDIX D. VSM DATA 104
APPENDIX E. SMED DATA 109
요약문 111
〈Table 1-1〉 Demand forecast per week 18
〈Table 2-1〉 Types of waste and their definitions 26
〈Table 2-2〉 Stages for waste elimination based on Lean manufacturing method 27
〈Table 2-3〉 Comparison of production systems 29
〈Table 2-4〉 Five primary elements of the Lean Manufacturing method. 31
〈Table 2-5〉 VSM Deployment Sequence 34
〈Table 2-6〉 SMED Implementation Sequence 36
〈Table 2-7〉 Characteristics of SME 43
〈Table 2-8〉 ARENA Software-Terms 46
〈Table 2-9〉 ARENA Software-Modules and their characteristics 47
〈Table 3-1〉 Calculation of processing time per product line-assembly process. 52
〈Table 3-2〉 Necessary data for the application of the Lean tools and their simulation 56
〈Table 4-1〉 Current Status VSM-Summary of indicators 57
〈Table 4-2〉 Weighted average processing time by product family 61
〈Table 4-3〉 Cycle time of process-Product family 61
〈Table 4-4〉 Waiting time-A1 product family 62
〈Table 4-5〉 Machine downtime and uptime of 2021 in hours 63
〈Table 4-6〉 First Pass Yield (FPY) data 64
〈Table 4-7〉 Takt time of processes in the manufacturing line 64
〈Table 4-8〉 Calculation of size of FIFO lane 68
〈Table 4-9〉 Summary of VSM future state of A1 TRACKSUIT product family 69
〈Table 4-10〉 Maximum weekly output of the manufacturing line (After improvement) 70
〈Table 4-11〉 Maximum weekly output vs forecast weekly demand (2022-2024) 70
〈Table 4-12〉 Preliminary stage SMED-PDC process 71
〈Table 4-13〉 Preliminary stage SMED-CE process 71
〈Table 4-14〉 Stage 3-Maximum operations optimization-DPC process 72
〈Table 4-15〉 Stage 3-Maximum operations optimization-CE process 72
〈Table 4-16〉 Comparison of times and improvement percentage-DPC and CE processes 73
〈Table 4-17〉 Summary of A1 TRACKSUIT product family after VSM and SMED 73
〈Table 4-18〉 Real System Performance and Simulated Model Information 76
〈Table 4-19〉 Simulation results and KPI's Measurement- Scenario 1 and scenario 2 77
〈Table 4-20〉 VA Time-Improvement Rate by scenario 79
〈Table 4-21〉 WIP-Improvement Rate by scenario 80
〈Table 4-22〉 Number Out-Growth Rate by scenario 82
〈Table 4-23〉 Two-sample t test with unequal variances 84
〈Figure 1-1〉 Operational process flow-Company "A" 17
〈Figure 1-2〉 Roadmap of this study 23
〈Figure 2-1〉 Five Elements of Lean Manufacturing 30
〈Figure 2-2〉 The Hierarchical structure of Lean approach 32
〈Figure 2-3〉 Scheme of times in a process-SMED. 35
〈Figure 2-4〉 Advantages of Lean Manufacturing 38
〈Figure 2-5〉 The effect of the LM system on the three pillars of sustainability 38
〈Figure 2-6〉 Lean Manufacturing tools and PDCA cycle 42
〈Figure 3-1〉 Flowchart of the methodology 49
〈Figure 3-2〉 Diagrama de Ishikawa 50
〈Figure 4-1〉 A1-TRACKSUIT Product Family-VSM Current State 58
〈Figure 4-2〉 Comparison of historical sales vs. Forecasted demand 59
〈Figure 4-3〉 Percentage of demand of product families by size 60
〈Figure 4-4〉 Percentage of demand of product family by order type 60
〈Figure 4-5〉 Takt time and cycle time comparison for all product family –Current State 65
〈Figure 4-6〉 VSM-Future State: A1 TRACKSUIT product family 67
〈Figure 4-7〉 Takt time vs. Cycle time for all product families-Future State 69
〈Figure 4-8〉 Comparison of improvement of times-DPC and CE processes 72
〈Figure 4-9〉 Demand Assessment Results -Input Analyzer 74
〈Figure 4-10〉 Manufacturing line-Layout 74
〈Figure 4-11〉 Simulation logic model 75
〈Figure 4-12〉 Scheduled Utilization-ARENA software 78
〈Figure 4-13〉 VA Time by Scenario-Process Analyzer 80
〈Figure 4-14〉 WIP by Scenario-Process Analyzer 81
〈Figure 4-15〉 Number Out by Scenario 83