Mapeamento do fluxo de valor como proposta de melhoria no segmento de cerâmica vermelha

Abstract

The red ceramic industry is inserted in an environment of high competitiveness, constant changes and faces complex challenges related to overproduction, high inventories, unnecessary movements and long waiting times in the production process. In this scenario, lean manufacturing presents an effective solution, offering a structured approach to eliminate waste, increase productivity and improve operational efficiency. This study focused on the application of the Value Stream Mapping (VSM) tool to identify critical points and opportunities for improvement throughout the production process in a red ceramic industry located in Itacoatiara, Amazonas, with the objective of proposing improvements and enhancing the value stream with the suggestion of a future state scientifically based on other studies. In order to address these problems, a qualitative-quantitative approach was adopted for data collection and analysis, divided into two distinct phases. The first phase was descriptive in nature and consisted of a detailed survey of the production line, with the objective of preparing the flowchart of the production process. In this context, the extensive direct observation technique was applied using a questionnaire that was answered by the main stakeholders in the process, including the production manager, mechanics, operators and planners, between June 1st and 30th, 2023 and as a result of the current state, a high stock of bricks of 669,177 units per month and a non value-added time of 10,065 minutes were identified. Based on this information, a scientific survey of the action plans applied using the VSM tool in other industries was carried out and consolidated using the 5W2H tool, as a suggestion to mitigate or eliminate the identified bottlenecks. The second phase had an explanatory character that consisted of identifying the factors that influenced the high stocks and production delays, resulting in the visualization of the improvements in the future state map. From this analysis, it is expected that the adoption of new technologies and the reduction of process times will result in economic, social and academic gains. By using VSM, the red ceramics industry will be able to achieve operational improvements, such as optimizing the production flow, making better use of resources, and increasing production capacity. In addition, the application of lean manufacturing can result in a more organized work environment, with better communication between teams, less rework, and the adoption of safer operational and environmental practices. In the academic field, the study also represents an opportunity for research and development, since the combination of the unique characteristics of this sector with the benefits of VSM offers important points for future research.