Aplicação de ferramentas lean manufacturing: estudo comparativo entre indústrias de bens de consumo não duráveis

Abstract

This research focuses on the proposal of applying lean manufacturing in the segment of non-durable consumer goods, through the action research method. The theme is delimited in an analysis efficiency of lean manufacturing tools in different productive segments of nondurable goods of the State of Rondônia. The segments of planned furniture, confection, butcher and bakery were analyzed. The quest to offer quality products with the shortest lead time is a challenge that begins with the transformation of the organizational culture. Analyzing the scenario in which there are various production processes, with various wastes, such as excessive handling, transportation, rework, overproduction, large inventories, unnecessary process, waiting and non-use of employees' intellects, the proposal was to evaluate the potential from tools in different production segments to create a leaner production process obtaining greater capacity for competitiveness in the market. The analysis made it possible to identify various problems in the production process, such as the distances traveled by components and operators, which leads to high transportation and handling costs, as well as wasted time searching for tools, raw materials and equipment preparations. The identification of the problems found was performed using the Value Flow Map and through the analysis of the material flow throughout the chain belonging to the production process, from the supplier to the end customer. Subsequently, performance indicators, lead time and employee productivity were calculated and analyzed. Then, improvement proposals were suggested in view of the problems encountered, highlighting the proposal of change of layout, environment organization, among others. As part of the methodology of this work, the following lean methodology tools were used, such as VSM, takt time, chronoanalysis, and standardization, quality at source, continuous flow and 5S. Significant gains were obtained in all the companies studied. At the butcher shop, there was an increase in productivity of around 26% and a reduction in costs with employees in the sector of around 75%. Regarding the planned furniture company, there was an increase of 105.92% in productivity. In clothing, there was an increase of 33.66% in productivity and a reduction in the movement of employees in the order of 93.10%. Finally, in the bakery, there was a 20.42% increase in productivity.