Digital transformation dispruts the balances on the world and influences the way of living, society, hobbies, health and even industries. In the manufacturing world, the Industrial Revolution is impacted by the digital transformation which brings big advantages and increases the capabilities of companies. By focusing on the manufacturing industry, there are significant investments in the digitalization of lean tools. Manufacturing companies have used lean tools and principles in order to reduce operational complexity and increase the productivity over decades. In fact, since the complexity of operations has increased within last years, It became difficult to manage operations only with the traditional lean tools. Industry 4.0 has emerged thanks to digitalization and has started to offer new approaches to solve the complexity problem and improving productivity. For companies, it’s crucial to decide how to deploy Industry 4.0 into their own culture and manage this transformation process. The purpose of this aim is to search the difficulties on the continuous improvement (CI) applications through the Plan-Do-Check-Act (PDCA) cycle in manufacturing companies and try to solve out those problems by using the benefits of the digitalization trend. To understand and analyze the PDCA application process, we used our previous internship experiences in manufacturing and banking sector, performed a survey with 71 participants from different manufacturing industries in order to understand their approach of CI, made an interview with a leading home appliances manufacturer ‘Whirlpool’. The survey results and company interview showed us that there are a couple of challenges which they face during Kaizen applications. Those are; involvement of the employees, the contribution of the top management, communication between the department, tracking of the PDCA steps and the respecting of the deadlines. Finally, We decided to improve a software prototype to eliminate all the problems that companies face during the PDCA cycle. Moreover, we have added additional features to this prototype thanks to the feedback from our tutors and our experiences. We believe that this idea will lead manufacturing companies to make more successful improvement projects and storage all these projects in the company database.
Le trasformazioni digitali hanno disgregato l’equilibrio nel mondo e influenzato il modo di vivere, la società, le abitudini, la salute e persino le industrie. Nel mondo della produzione, la Rivoluzione Industriale è influenzata dalle trasformazioni digitali che portano grandi vantaggi e incrementano le capacità delle aziende. Focalizzandosi sull'industria manifatturiera, troviamo investimenti significativi nella digitalizzazione degli strumenti di lean che sono stati utilizzati per ridurre le operazioni più complesse e aumentare la produttività per decenni. Negli ultimi anni la complessità delle operazioni è aumentata ed è ormai difficile gestirle solamente tramite gli strumenti tradizionali. L’Industria 4.0 è emersa grazie alla digitalizzazione e ha cominciato a offrire nuovi metodi per risolvere i problemi più complessi e incrementare la produttività. Per le aziende è cruciale decidere in che modo allineare l’Industria 4.0 nella propria cultura e gestire la trasformazione dei processi. L’obiettivo è quello di cercare le difficoltà nei continui miglioramenti (CI) attraverso il ciclo Plan-Do-Check-Act (PDCA) nelle aziende manifatturiere e tentare di risolvere tali problemi utilizzando i vantaggi della digitalizzazione. Per capire e analizzare il processo di applicazione PDCA, abbiamo utilizzato le nostre precedenti esperienze di tirocinio nel settore manifatturiero e bancario, eseguendo un sondaggio con 71 partecipanti provenienti da diversi settori produttivi, al fine di comprendere il loro approccio al (CI) in aggiunta anche un'intervista a uno dei leader produttore nel settore elettrodomestico “Whirlpool”. I risultati del sondaggio e il colloquio aziendale hanno mostrato che ci sono un paio di sfide che hanno dovuto affrontare durante l’applicazioni del Kaizen. Quest’ultime sono; coinvolgimento dei dipendenti, contributo del top management, comunicazione tra i dipartimenti, tracciamento dei passi PDCA e rispetto delle scadenze. Infine, abbiamo deciso di migliorare un prototipo software che aiuti a eliminare tutti i problemi che le aziende devono affrontare durante l'applicazione del PDCA, successivamente sono state aggiunte altre funzionalità in base ai feedback dei nostri tutor e grazie alle esperienze acquisite. Riteniamo che quest’idea porterà le aziende manifatturiere a realizzare progetti di miglioramento di maggior successo e archiviare tutte queste informazioni nel database aziendale.
Digitalisation of lean manufacturing tools : the PDCA transformation from paper to e-PDCA
ARSAL, HUSEYIN HUSNU;CON, MUSTAFA
2017/2018
Abstract
Digital transformation dispruts the balances on the world and influences the way of living, society, hobbies, health and even industries. In the manufacturing world, the Industrial Revolution is impacted by the digital transformation which brings big advantages and increases the capabilities of companies. By focusing on the manufacturing industry, there are significant investments in the digitalization of lean tools. Manufacturing companies have used lean tools and principles in order to reduce operational complexity and increase the productivity over decades. In fact, since the complexity of operations has increased within last years, It became difficult to manage operations only with the traditional lean tools. Industry 4.0 has emerged thanks to digitalization and has started to offer new approaches to solve the complexity problem and improving productivity. For companies, it’s crucial to decide how to deploy Industry 4.0 into their own culture and manage this transformation process. The purpose of this aim is to search the difficulties on the continuous improvement (CI) applications through the Plan-Do-Check-Act (PDCA) cycle in manufacturing companies and try to solve out those problems by using the benefits of the digitalization trend. To understand and analyze the PDCA application process, we used our previous internship experiences in manufacturing and banking sector, performed a survey with 71 participants from different manufacturing industries in order to understand their approach of CI, made an interview with a leading home appliances manufacturer ‘Whirlpool’. The survey results and company interview showed us that there are a couple of challenges which they face during Kaizen applications. Those are; involvement of the employees, the contribution of the top management, communication between the department, tracking of the PDCA steps and the respecting of the deadlines. Finally, We decided to improve a software prototype to eliminate all the problems that companies face during the PDCA cycle. Moreover, we have added additional features to this prototype thanks to the feedback from our tutors and our experiences. We believe that this idea will lead manufacturing companies to make more successful improvement projects and storage all these projects in the company database.| File | Dimensione | Formato | |
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Digitalisation of Lean Manufacturing Tools.pdf
non accessibile
Descrizione: Thesis report
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4.12 MB
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Adobe PDF
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4.12 MB | Adobe PDF | Visualizza/Apri |
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https://hdl.handle.net/10589/142405