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Der Lean Ansatz revolutionierte die industrielle Produktion und wurde vom spezifischen Produktionssystem zu einem ganzheitlichen Managementansatz entwickelt. Der Einsatz erfolgte in der Vergangenheit vornehmlich in großen Unternehmen als diskontinuierlicher Projektansatz. Die Besonderheiten kleiner und mittlerer Unternehmen (KMU) blieben unbeachtete, wodurch im Schrifttum eine Lücke entstand und die Lean Implementierung in KMU lediglich temporär erfolgreich war. Die vorliegende Arbeit stellt die Lean Implementierung in KMU in den Vordergrund. Basierend auf Erkenntnissen der Forschung zum Lean Management in Verbindung mit den Charakteristiken von KMU schließt das erarbeitete Implementierungsmodell die identifizierte Forschungslücke. Das Modell beschreibt die Lean Einführung in KMU anhand eines Implementierungsprozesses mit differenzierbaren Prozessschritten innerhalb von vier Phasen. Ausgehend von der Vorbereitung wird die Implementierung auf strategischer und auf operativer Ebene realisiert. Begleitende Maßnahmen unterstützen die sukzessive Lean Implementierung, während die abschließende Phase zur Sicherung der Nachhaltigkeit den langfristigen Lean Einsatz gewährleistet. Die Berücksichtigung von Lean Methoden und Elementen aus Sicht von KMU rundet das Modell ab.
The European Parliament and Council has defined a mandatory specific emission target of 95 g CO2/km by 2020 for passenger cars. Vehicle weight is a significant factor contributing to fuel consumption. Reducing the weight of the vehicle can be one promising option for decreasing CO2 emissions, which becomes a top priority for the automotive industry. In this research, two approaches were used to address the need. One involved developing structural parts using fibre reinforced plastics (FRP), and the other involved designing and developing FRP–metal hybrid laminates, which were constructed by reinforcing FRP locally to the metal surface. Existing joining techniques such as riveting, bolting, adhesive joining, ultrasonic welding, and flow drill joining techniques require additional processing steps to perform the joining, which could considerably increase processing time, cost, and energy expenditure. The present work describes a method to join FRP and metals using the adhesion strength of the investigated polymers. The developed FRP–metal hybrid laminates combine the advantages of metal and FRP together. Steel hot-stamping is known to yield very high strength. Fibre reinforced plastic–metal hybrid laminates were developed using hot stamped steels to transfer their superior mechanical properties to the final structure. To utilize the complete lightweight potential of thermoset and thermoplastic polymers, FRPs and FRP–metal hybrid laminates were developed using both the polymers. Along with this increased demand for FRP structures, there is growing interest in a repair technique in the automotive industry. The second objective of this thesis consists of designing and developing a new repair technique, which regains the strength and stiffness properties of the damaged part. The existing scarf repair technique is not suitable for thin laminates, which have limited access to the damaged area. Perforation damages were introduced into the FRP structures using a low-velocity impact load. A modified injection repair technique is used to repair these damaged FRP structures. Non-destructive techniques were utilized to understand the damage and the effectiveness of the repair.