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1

Doskonalenie procesów logistycznych według metodyki DMAIC

Pisz Iwona, Wyrwich-Płotka Sabina

Gospodarka Materiałowa i Logistyka

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2022

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nr 5

23--35

PL

Współczesne organizacje działające na konkurencyjnym, globalnym rynku obserwują znaczący wzrost zainteresowania problematyką zarządzania jakością początkowo wyrobów i usług, a w konsekwencji systemów zarządzania, co powoduje rozwój nowych metod doskonalenia jakości w organizacjach. Proces ten determinowany jest coraz mocniejszym naciskiem na obniżenie kosztów produkcji i generowanie oszczędności w połączeniu z redukcją zbędnych kosztów. W efekcie powstały korzystne warunki do rozwoju nowych metod zarządzania jakością, takich jak: Six Sigma, Lean Manufacturing i Kaizen, które są szeroko rozpowszechnione w organizacjach, w tym zwłaszcza w przedsiębiorstwach z różnych branż i o różnych profilach działalności na całym świecie. W artykule zaprezentowano wybraną koncepcję doskonalenia procesów logistycznych według metodyki DMAIC w ujęciu teoretycznym i praktycznym. Celem artykułu jest przedstawienie możliwości praktycznej aplikacji koncepcji doskonalenia procesów według metodyki DMAIC, zmierzającej do redukcji wartości złomu produkcyjnego w przedsiębiorstwie wytwarzającym okucia okienne.

EN

Contemporary organizations, that are operating in a competitive, global market observe a significant increase of interest in the issues of quality management, initially in products and services, and in the consequence in the management systems, which results in the development of new methods of quality improvement in organizations. This process is determined by increasing emphasis on reducing production costs and generating savings combined with the reduction of unnecessary costs. As a result, advantageous conditions were created for the development of new quality management methods, such as: Six Sigma, Lean Manufacturing and Kaizen, which are widespread in many organizations, especially in enterprises of various industries and business profiles around the world. The article presents a selected concept of the improvement of logistics processes according to the DMAIC methodology in theoretical and practical terms. The aim of the article is to present the possibility of a practical application of the process improvement concept according to the DMAIC methodology, heading to reducing the value of production scrap in an enterprise that produces window fittings.

2

Improvement of warehouse processes by implementation of lean Six Sigma in global supply chain

Kamińska Monika

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

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2021

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z. 154

81--94

EN

Purpose: Nowadays businesses concentrate on the highest efficiency and lowest waste, that’s why some organizations implement Lean Six Sigma as a complete package of adapted tools. This article evaluates the implementation of the Lean Six Sigma method. Design/methodology/approach: The case study presents an approach and project scheme adjusted by Global Supply Chain Manufacturer. This paper shows the results of the LSS method implementation in the internal and 3rd Party Logistics distribution center. Findings: This warehouse process improvement method uses tools like ECRS for process map, Cause-and-Effect Diagram, 5Why&1How analysis, Spaghetti Diagram, Flow Process Analysis sheet, and Action Plan. Practical implications: This article evaluates three logistics processes in two distribution centers where LSS has been applied: handling process and twice picking process. Results provide enhanced process and saving for owned DC (0,8m€) and lower rates in 3P DC (saving 2m€). Originality/value: Project was so satisfactory for the corporation that it developed global online training. The case company represents a significant source of information to gain understandings of the effects of implementing LSS in warehousing services.

3

Implementation of the Six Sigma methodology in increasing the capability of processes in the company of the furniture industry of the Slovak Republic

Simanova Ľubica, Gejdoš Pavol

Management Systems in Production Engineering

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2021

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nr 1 (29)

54--58

EN

The aim of the article is to present the results of a case study focused on the implementation of the Six Sigma methodology in order to improve the quality and increase the efficiency of furniture production processes. Positive results of implementation after the implementation of corrective measures were achieved in the values of process capability coefficients, reduction of nonconformities and subsequent reduction of DPMO, increase of the values of the level of efficiency and sigma of the critical process.In the processing of the results, classical methods of research work were used such as analysis, synthesis, comparison, descriptive statistics, coefficients Cp a Cpk, DPMO, level of efficienty and sigma,and also graphic methods.

4

Six sigma methodology used to improve the mechanical properties for friction stir weldingof aluminum pipes

Sabry Ibrahim

Management and Production Engineering Review

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2020

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Vol. 11, No. 1

73--78

EN

This paper presents a new welding quality evaluation approach depending on the analysis by the fuzzy logic and controlling the process capability of the friction stir welding of pipes (FSWoP). This technique has been applied in an experimental work developed by alternating the FSW of pipes process major parameters: rotation speed, pipe wall thickness and travel speed. variable samples were friction stir welded of pipes using from 485 to 1800 rpm, 4–10 mm/min and 2–4 mm for the rotation speed, the travel speed, and the pipe wall thickness respectively. DMAIC methodology (Defining, Measuring, Analyzing, Improving, Control) has been used as an approach to analyze the FSW of pipes, it depends on the attachment potency and technical commonplace demand of the FSW of pipes process. The analysis controlled the Al 6061 friction stir welded joints’ tensile strength. To obtain the best tensile strength, the study determined the optimum values for the parameters from the corresponding range.

5

Impact of Manufacturing Tolerances on Stress in a Turbine Blade Fir-Tree Root

Moneta Grzegorz, Jachimowicz Jerzy

Fatigue of Aircraft Structures

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2020

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Iss. 12

92--101

EN

Low Cycle Fatigue (LCF) is one of most common mechanisms behind turbine blade failures. The reason is high stress concentration in notch areas, like fir-tree root groves, which can cause cyclic stress beyond the safe threshold. The stress levels strictly depend on the manufacturing accuracy of the fir-tree lock (for both fitted together: blade root and disk groove). The probabilistic study aimed at determination of stress was performed using Finite Element Method (FEM) simulation on a population of 1000 turbine models (disk + blades +friction dampers), where fir-tree lock dimensions were sampled according to the normal distribution, within limits specified in the documentation. The studies were performed for different manufacturing quality levels: 3-Sigma, 6-Sigma and 3-Sigma with tolerance ranges reduced twice. Based on the results, the probabilistic distributions, probabilities and expected ranges of values could be determined for: material plastification, stress, strain, LCF lifetime, etc. The study has shown how each tooth of the root is loaded and how wide a stress range should be expected in each groove. That gives information on how the definition of tolerances should be modified to make the construction more optimal, more robust, with lower likelihood of damage, taking into account the cost-quality balance. It also shows how the Six Sigma philosophy can improve the safety of the construction, its repeatability and predictability. Additionally, the presented numerical study is a few orders of magnitude more cost- and time-effective than experiment.

6

Structured Problem Solving: combined approach using 8D and Six Sigma case study

Sharma Mithun, Sharma Shilpi, Sahni Sanjeev

Engineering Management in Production and Services

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2020

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Vol. 12, no. 1

57--69

EN

The current research study aimed to explore the utility of selected problem-solving tools and techniques in root-cause analysis to demonstrate their practical application. An experimental research design adopting a positivist empirical approach with a deductive strategy was followed to assess the effectiveness of a combined (8D & Six Sigma) problem-solving approach in reducing a high defects rate of a mixer shower assembly line. A novel application of the 8D framework in combination with Six Sigma and other analytical tools was found highly effective in reducing the reject rate from 11.84% to 0.11%. Successful identification of the root cause led to the implementation of permanent corrective action ensuring a long-term stable assembly process. The research study provided a problem-solving framework that was found effective in resolving a complex problem and implementing long-term corrective action in an assembly production line. However, this framework can be used in other industries. The research study provides a solution to a high number of leak rejects in a subassembly where “O-seals” are used between mating parts. It also provides analytical tools that were found highly effective during the problem-solving process.

7

Wprowadzenie do metody Six Sigma

Ingaldi Manuela

Zeszyty Naukowe. Quality. Production. Improvement

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2019

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No. 1 (10)

119--130

PL

Six Sigma to nowoczesny i bardzo rygorystyczny sposób zarządzania organizacjami, których celem jest dążenie do doskonałości. Metoda opiera się na TQM oraz ciągłym doskonaleniu. Cele artykułu było wprowadzenie czytelnika w podstawy metody Six Sigma. Na początku zdefiniowano pojęcie Six Sigma oraz opisano pochodzenie nazwy. Zestawiono etapy wdrażania metody Six Sgima w przedsiębiorstwie i zasady Six Sigma. Scharakteryzowano także projekt DMAIC.

EN

Six Sigma is a modern and very rigorous way of managing organizations which aim is to strive for excellence. The method is based on TQM and continuous improvement. The purpose of the paper was to introduce the reader to the basics of the Six Sigma method. At the beginning, the term Six Sigma was defined and the origin of the name was described. The stages of Six Sigma implementation in the company and Six Sigma principles have been summarized. The DMAIC project was also characterized.

8

Analysis and improvement of the galvanized wire production process with the use of dmaic cycle

Knop Krzysztof

Quality Production Improvement - QPI

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2019

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Vol. 1, Iss. 1

551--558

EN

The article presents the results in the scope of analysis and improvement of the galvanized wire production process with the use of Six Sigma's DMAIC cycle. The basic problem was identified - incorrect wire diameters after galvanizing and specific tools and methods were used to analyze this problem and look for its solution. The potential of Pareto analysis, SPC method, control plan, 5WHY analysis was used. As a result of the analyzes carried out, the source cause was identified - contaminated containers dispensing the preparation maintaining the temperature in the galvanizing unit. To eliminate the problem, maintenance of the machine used to cover the bare wire with zinc was carried out, which allowed to achieve the following results: standstills at the Drawing and Galvanizing Department were eliminated, the duration of the manufacturing process and the percentage of products beyond the specification were significantly reduced.

9

Validating a destructive measurement system using Gauge R&R — a case study

Sharma Mithun, Sahni Sanjeev P., Sharma Shilpi

Engineering Management in Production and Services

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2019

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Vol. 11, no. 4

34--42

EN

The research study aims to evaluate the precision of the measurement system using Gauge R&R. An experimental research design adopting a positivist empirical approach with deductive strategy was followed to assess the effectiveness of Crossed Gauge R&R technique for validating a measurement system using destructive testing. Crossed Gauge R&R technique in Minitab was found to be highly effective in quantifying different components of measurement variation relative to process variation. Clue generation from the Crossed Gauge R&R study combined with manufacturing and measurement process know-how helped in identifying and eliminating the root causes for measurement variation. Overall Crossed Gauge R&R proved successful in validating the burst strength test equipment. However, it should be noted that manufacturing and test equipment played an equally important part in developing and executing the gauge R&R study and accurately analysing the results. So, Crossed Gauge R&R should be used as an aid rather than the solution for measurement system validation.

10

Reduction of defects in the lapping process of the silicon wafer manufacturing: the Six Sigma application

Sharma Mithun, Sahni Sanjeev P., Sharma Shilpi

Engineering Management in Production and Services

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2019

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Vol. 11, no. 2

87--105

EN

Aiming to reduce flatness (Total Thickness Variation, TTV) defects in the lapping process of the silicon wafer manufacturing, it is crucial to understand and eliminate the root cause(s). Financial losses resulting from TTV defects make the lapping process unsustainable. DMAIC (Define, Measure, Analyse, Improve and Control), which is a Six Sigma methodology, was implemented to improve the quality of the silicon wafer manufacturing process. The study design and the choice of procedures were contingent on customer requirements and customised to ensure maximum satisfaction; which is the underlying principle of the rigorous, statistical technique of Six Sigma. Previously unknown causes of high TTV reject rates were identified, and a massive reduction in the TTV reject rate was achieved (from 4.43% to 0.02%). Also, the lapping process capability (Ppk) increased to 3.87 (beyond the required standard of 1.67), suggesting sustainable long-term stability. Control procedures were also effectively implemented using the techniques of poka yoke and control charts. This paper explores the utility of Six Sigma, a quality management technique, to improve the quality of a process used in the semiconductor industry. The application of the Six Sigma methodology in the current project provides an example of the root cause investigation methodology that can be adopted for similar processes or industries. Some of the statistical tools and techniques were used for the first time in this project, thereby providing new analysis and quality improvement platform for the future. The article offers a deeper understanding of the factors that impact on the silicon wafer flatness in the lapping process. It also highlights the benefits of using a structured problem-solving methodology like Six Sigma.

11

Increasing the implementation capability of Lean Six Sigma through the integration with a learning organisation concept

Vlasov V.

Zarządzanie Przedsiębiorstwem

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2018

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Vol. 21, nr 4

30--36

EN

Companies throughout the world have always been working on improving their operations and challenging their bottom lines. With a the increased competition triggered by globalization, it has become vital for them to run their businesses in the most efficient and effective ways.

12

Six Sigma as a method of improving the quality of service process

Kowalik K.

Production Engineering Archives

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2018

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Vol. 19

10--15

EN

The objective of the analysis conducted and described in this paper has been to present the practical application of the Six Sigma method based on the DMAIC cycle in improving the quality of the service process. The first part of the article contains the theoretical framework of six sigma and the issue of using its tools in the aspect of services. Afterwards, there has been calculated the initial sigma value which indicated the need for improvement. Measurement phase has been developed by the value stream mapping, process FMEA and customer survey which results have been analyzed in Pareto chart and fishbone diagram. Improve phase includes the Impact&Effort Matrix and target sigma level that can be achieved as a result of failures reducing and service quality improvement.

13

Lean Banking – innowacyjne podejście do bankowości

Lizak M.

Zeszyty Naukowe. Quality. Production. Improvement

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2017

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No. 2 (7)

1--11

PL

W rozdziale dokonano analizy zagadnienia innowacyjnego podejścia do bankowości- Lean Banking w świetle literatury przedmiotu. Skoncentrowano się głównie na zasobach literatury międzynarodowej jak i krajowej. Szczupłe zarządzanie ma na celu ciągłe podnoszenie umiejętności pracowników. Poruszono również problematykę Six Sigma i Lean Banking. W końcowej fazie zaprezentowano wnioski dotyczące implementacji tej koncepcji w przedsiębiorstwach działających w sektorze finansowym. Zauważono tutaj innowacyjność koncepcji Lean Banking, która wkracza do bankowości i należy ją dalej rozwijać

14

Use of Six Sigma in the production process - case study

Midor K.

Systemy Wspomagania w Inżynierii Produkcji

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2017

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Vol. 6, iss. 4

147--152

EN

Issues related to the quality of the final product and the individual components that comprise it are important in every branch of the industry. This is especially true for the automotive branch, where the consequences of quality errors are very severe and costly. The article presents the use of the Six Sigma method for the improvement of the process of height measurement of a controller board chip in a production stream for a premium-class client. The method used, which can be defined mathematically, allowed for minimising the causes for excessive rejection rates of the element in question, which was presented in the article.

PL

Zagadnienia związane z jakością produktu finalnego i poszczególnych komponentów składających się na produkt końcowy są ważne w każdej branży. Szczególnie w branży motoryzacyjnej, gdzie konsekwencje błędów jakościowych są bardzo dotkliwe i kosztowne. Celem artykułu jest zaprezentowanie zastosowania metody Six Sigma do doskonalenia procesu pomiaru wysokości chipa na płytce kontrolera na strumieniu produkcyjnym dla klienta klasy Premium. Zastosowana metoda, którą można zdefiniować w sposób matematyczny, pozwoliła zminimalizować przyczyny zbyt wysokiego odrzutu wybranego elementu, co zostanie zaprezentowanie w artykule.

15

The Importance of Productivity of Processes in Overcoming the Effects of the Economic Crisis

Milewski D., Wiśnicki B., Masoulas B.

Problemy Transportu i Logistyki

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2017

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nr 3 (39)

105--118

EN

The objective of the paper is to present the role productivity and thus: (a) diminish the impact of the global financial crisis and (b) provide the means for growth not only for companies but also for a whole economy. Special emphasis was placed on methods of increasing productivity – Lean Manufacturing and Six Sigma methodology. The authors studied research literature and case studies of companies which have implemented Lean – Six Sigma methodology, and proved that (a) the implementations of Lean – Six Sigma methodology have improved process efficiency, and (b) such process efficiency improvements helped the companies overcome the effects of the financial crisis. The studied companies originate from different industrial sectors and from different countries in the world. As complement to the research results found in the literature and also as a comparison authors made also research concerning Poland and Greece.

PL

Celem artykułu jest przedstawienie roli produktywności, która jest związana z zmniejszeniem wpływu światowego kryzysu finansowego i zapewnieniem środków do wzrostu nie tylko dla firm, ale także dla całej gospodarki. Szczególny nacisk położono na metody zwiększania produktywności – metodologię Lean Manufacturing i Six Sigma. Autorzy przeanalizowali literaturę badawczą i studia przypadków firm, które wdrożyły metodologię Lean – Six Sigma, i udowodnili, że wdrożenia metodologii Lean – Six Sigma poprawiły efektywność procesu oraz że taka poprawa wydajności procesu pomogła firmom pokonać skutki kryzysu finansowego. Badane firmy pochodzą z różnych sektorów przemysłu i z różnych krajów świata. Uzupełnienie wyniki badań w literaturze oraz własnych, dokonano również badań dotyczących Polski i Grecji.

16

Optimization of turning process parameters by Taguchi-based Six Sigma

Das P. P., Gupta P., Ghadai R. K., Ramachandran M., Kalita K.

Mechanics and Mechanical Engineering

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2017

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Vol. 21, nr 3

649--656

EN

In this paper, Six Sigma approach is used for improving the quality process outputs in turning of Galvanized Iron. The objective is to optimize the turning parameters and maximize the MRR (Material Removal Rate). A L16 orthogonal array based on Taguchi experiments consisting of three controlling factors viz. spindle speed, feed rate, and depth of cut, each with four levels as required in traditional DOE setting is used here. Taguchi’s parameter design offers an approach in Design of Experiments (DOE) with control parameters optimization to attain best outcome. An orthogonal array offers a set of balanced least experiments which help in data analysis and prediction of optimum results. For each experiment, the Material Removal Rate (MRR) is calculated. The Taguchi method results in reducing the quality characteristic variation due to uncontrollable parameter through the study of response variation using the Signal to Noise (S/N) ratio by the use of Minitab 16 software. Moreover, statistical investigation shows that standard deviation and mean value of confirmation run data are reduced when compare with before Taguchi design run data was performed.

17

Optimization of the soldering process by the DMAIC methodology

Zasadzień M.

Production Engineering Archives

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2016

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Vol. 11, No. 2

6--10

EN

The chapter presents use of the DMAIC method for the analysis and improvement of the process of soldering pins in a plug connecting a bundle of wires to the board of a controller, part of the steering system of a passenger car. The main problem in the soldering process - an unsatisfactory share of bad soldered connections between the board and the plug and the instability of that number - was identified using a five-phase improvement process. Key points and main causes of the defect were pointed out, and process improvement measures suggested. Due to the analysis conducted and the correct implementation of improvement measures the share of defective connections has been decreased twofold.

18

Composite testing laboratory performance development based on Lean Sigma approach - case study

Kozaczuk K., Zalewska M.

Prace Instytutu Lotnictwa

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2016

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Nr 4 (245)

60--69

EN

The paper presents a case study describing the implementation of a Lean Sigma methodology to the Composite Testing Laboratory (CTL) of Centre for Composite Technologies of the Warsaw Institute of Aviation (WIA) in order to develop the overall performance and meet customer requirements. The article presents general requirements associated with composite testing and Lean Sigma technique as a combination of two well-known quality improvement methodologies which rely on waste and production cycle time reduction (Lean) as well as quality improvement and incremental reduction of detects (Six Sigma). I he whole process ot Lab improvement is depicted using the Six Sigma structured method DMAIC (Define, Measure, Analyse, Improve, Control). Each phase shows the actions that were undertaken with customer and management support from 2014 to 2015 as well as the Lean Sigma tools that were applied. Conclusions show the improvements that were observed in CTL after the project accomplishment and the experiences gained.

PL

Artykuł prezentuje studium przypadku opisujące wdrożenie metodyki Lean Sigma w Laboratorium Badań Kompozytów Centrum Technologii Kompozytowych, Instytutu Lotnictwa, w celu zwiększenia wydajności Laboratorium oraz spełnienia wymagań klienta. W artykule zostały przedstawione ogólne wymagania w zakresie badań kompozytów oraz technika Lean Sigma jako kombinacja dwóch dobrze znanych metodologii poprawy jakości, które opierają się na redukcji strat i czasu cyklu produkcyjnego (Lean) jak również poprawy jakości i stopniowej redukcji defektów (Six Sigma). Całościowy proces polepszenia Laboratorium jest opisany zużyciem metody DMAIC (Zdefiniuj, Zmierz, Zanalizuj, Usprawnij, Kontroluj). W każdej z faz opisane zostały akcje, które zostały podjęte przy wsparciu klienta oraz zarządu od 2014 do 2015 oraz narzędzia Lean Sigma jakie zostały użyte. W podsumowaniu zostały przedstawione ulepszenia Laboratorium po zakończeniu projektu oraz nabyte doświadczenia.

19

Lean Six Sigma jako przykład ewolucji sposobów rozwiązywania problemów w przemyśle

Świtek S.

Organizacja i Zarządzanie : kwartalnik naukowy

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2016

|

nr 2

157--177

PL

Artykuł przedstawia rozwój podejść do rozwiązywania problemów w przemyśle opartych na metodzie naukowej. Rozwój systemów produkcyjnych w kierunku produkcji masowej oraz zmieniające się wymagania klienta zmienił traktowanie problemów jakościowych – uprzednio klasyfikowanych jako techniczne teraz stały się czynnikiem ekonomicznym wpływającym na wynik finansowy firmy. W związku z powyższym techniki rozwiązywania problemów musiały się również zmieniać.

EN

In the article presented development of problem solving approaches used in industry based on the scientific method. Growth of production systems into direction of mass production and changing over time customer requirements has modified defining quality related problems – formerly classified as technical, nowadays they have become economic influential factor affecting business results of any organization. Consequently, problem solving techniques had to evolve, too.

20

Lean Tools and Techniques for Global Project Management

Witczyńska K. B.

Logistics and Transport

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2016

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Vol. 32, No. 4

29--38

EN

The purpose of this article is to show the essence of Lean Management, management practices applied by companies, and the possibility for this method to be used to further improve management in an organisation. This article uses a review of existing literature, studies and reports relating to management.