Product mix of standardization with the use of Lean Manufacturing for production planning optimization



Lean Manufacturing, product mix, setup, flexibilization, case study.


From the optimization of production setup - Lean Manufacturing - reduce setup times based on this methodology, together with the product mix. It’s attempted to record the problems encountered during setup reduction study, and consequently the dissemination of knowledge through training, on the factory floor, in order to standardize the tools and techniques to be used. As endpoint will be used production and productivity gains in the production line where they held the case study, which is a multinational company in the industrial instrumentation field of high precision. At the end of the article will be proposed suggestions for future studies as a way to complement the methodology proposed in this study as well as possible points of improvement to be explored.


Ball, P. (2015). Low energy production impact on Lean flow. Journal of manufacturing Technology Management, Vol. 26 pp. 412-428.

Belbin, M. (2010). Management Teams: why they succeed or fail. Butterworth Heinemann, 3rd ed.

Bhamu, J. & Sangwan, K. S. (2014). Lean manufacturing: literature review and resarch issues. International Journal of Operations & Production Management, v. 34, n. 7, p. 846-940.

Coimbra, E. A. (2009). Total Flow Management: Achieving Excellence with Kaizen and Lean Supply Chains. Kaizen Institute.

Chopra, A., Kalra P. & Jawalkar, C. S. (2014). Reduction of Process Lead Time through Value Stream Mapping: A Case Study of Indian Electronics Industry, International Journal of Advanced Engineering Applications, Vol.7, pp.19-26,.

Demarrais, K., B., & Lapan, S. (2004). Foundations for Research Methods of Inquiry in Education and the Social Sciences. Mahway, NJ: Lawrence Erlbaum Associates Inc.

Dema, P. (1995). Metodologia científica em ciências sociais. 3ª ed, São Paulo, Atlas.

Deros, B. M., Mohamad, D., Idris, M. H. M., Rahman, M. N. A., Ghani, J. A. & Ismail, A. R. (2011). Setup time reduction in an automotive battery assembly line. International Journal of System Application, Engineering & Development.

Eisenhardt, K., M. (1989). Building Theories from Case Study Research, The Academy of Management Review, Vol. 14, No. 4 p. 532-550.

Feldimann, M. & Biskup, D. (2003). Single-Machine Scheduling for Minimizing Earliness and Tardiness Penalties by Meta-heuristic Approaches, Computers and Industrial Engineering, v. 44, p. 307–323.

Gil. A. C. (2002). Como elaborar projetos de pesquisa. São Paulo: Atlas.

Godinho F. M. Fernandes, F. C. F. (2014). Manufatura Enxuta: Uma Revisão que Classifica e Analisa os Trabalho Apontando Perspectivas de Pesquisas Futuras. Gestão & Produção. v. 11, n. 1, p. 1-19.

Goubergen, D. V. & Landeghem, H. V. (2012). Rules for integrating fast changeover capabilities into new equipment design. Robotics and Computer Integrated Manufacturing.

Kulkarni H. & Bhatwadekar S. (2015). Performance of decomposition procedures for job shop scheduling problems with bottleneck machines, International Journal of Latest Trends in Engineering and Technology, 5:1, p. 245-254

Goriwondo, W. M., Mhlanga, S. & Marecha, A. (2011). Use of The Value Stream Mapping Tool For Waste Reduction In Manufacturing. Case Study For Bread Manufacturing In Zimbabwe, International Conference on Industrial Engineering and Operations Management, pp.236-241.

Jebaraj, S. & Uthiyakumar, B. (2013). The use of SMED to eliminate small stops in a manufacturing firm, Journal of Manufacturing Technology Management, Vol. 24.

Kumar, S.V., Mani, V.G.S. & Devraj, N. (2015). Production Planning and Process Improvement in an Impeller Manufacturing Using Scheduling and OEE Techniques. International Conference on Advances in Manufacturing and Materials Engineering.

Laugen, B. T., Acur, N. & Boer, H.(2005). Best manufacturing practices. What do the best-performing companies do? International Journal of Operations & Production Management. Vol. 25, pp. 131-150.

Lopes, M. C. (2008). Modelo para Focalização da Produção com Células de Manufatura. Universidade Federal de Santa Catarina. Dissertação de Mestrado em Engenharia de Produção.

Maccarthy, B. L. & Liu, J. Y. (1993). Adressing the gap in the scheduling research: a review of optimization and heuristic methods in production scheduling. International Journal of Production Research, London, V.31

Mark, A. (2004). Setup reduction: at the heart of Lean Manufacturing. Modern Machine Shop, Vol. 76.

Mason, S., Fowler, J., Carlyle, W. & Montgomery, D. (2005). Heuristics for minimizing total weighted tardiness in complex job shops. International Journal of production Research. p. 1943-1963.

McIntosh, R.I., Culley, S. J., Mileham, A. R. & Owen, G. W. (2010). A critical evaluation of Shingo’s SMED methodology, International Journal of Production Rsearch, Vol.38.

Miltenburg, J. (2001). U-shaped production lines: A review of theory and practice. International Journal of Production Economics. Volume 70, Issue 3, Pages 201-214.

Mönch, L. & Zimmermann J. (2011) A computational study of a shifting bottleneck heuristic for multi-product complex job shops, Production Planning & Control, 22:1, p. 25-40.

Moreira, A. M., Silva, R.S. & Palma, M. A. M. (2010). Revista de Gestão e Projetos - GeP, São Paulo, v. 1, n. 2, p 128-146.

Moxham, C. & Greatbanks, R. (2001). Prerequisites for the implementation of the SMED methodology. A study in textile processing environment. International Journal of Quality & Reliability Management, volume 18, pp. 404-414.

Ohno, T. (2002). O Sistema Toyota de Produção. Além da Produção em Larga Escala. Porto Alegre: Bookman, 2002.

Petrobrás. Planos de gestão. Disponível em:, Acessado em 13/04/2016 às 20:19 hrs.

Reik, M.P., McIntosh, R.I., Culley S.J., Mileham, A.R., Owen, G.W. (2006). A formal design for changeover methodology. Part 1: Theory and background. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 220, p. 1225.

Rong-Lei, S., Han D., Youlun X. & Runshen D. (2006). Interative Learning Scheduling: a combination of optimization and dispatching rules, Journal of manufacturing Technology Management, pp. 298-305.

Seth, P. P., Vivek A. D. & Hiren R. K. (2014). Value Stream Mapping: A Case Study of Automobile Industry, International Journal of Research in Engineering and Technology, Vol.03, pp.310-314.

Santos, A. (1999). Application of flow principles in the production management of construction sites. PhD Thesis. Salford, England: School of Construction and Property Management.

Shingo, S. (2000). Sistema de Troca Rápida de Ferramenta. Porto Alegre: Bookman.

Turkyilmaz, A., Gorener, A. & Baser, H. (2013). Value Stream Mapping: Case Study in a Water Heater Manufacturer, International Journal of Supply Chain Management, Vol 2, pp. 32-39.

United Nations. (2005). World Investment Report 2005: Transnational Corporations and the Internationalization of R&D. United Nations, New York & Geneva.

Venkatraman, K., Vijaya, B., Muthu V. K. & Elanchezian, C. (2014). Application of Value Stream Mapping for Reduction of Cycle Time in a Machining Process, Procedia Material Science, pp.1187-1196.

Vermulm, R. & Erber, F. (2002). Estudo da competitividade de cadeias integradas no Brasil: impactos das zonas de livre comércio. Cadeia: Bens de Capital. Campinas: Unicamp, IE e MDIC.

Wan, G. E., Yen, B. P. C. (2002). Tabu search for single machine scheduling with distinct due windows and weighted earliness, European Journal of Operational research, v. 142, p. 271-281.

Yamagar, A.C & Ranavan, P.M. (2010). Material Management by using Lan Manufacturing Principles. A case study. Proceedings of the 2nd International Conforence on manufacturing Engineering, Quality and production Systems.

Womack, J. P., Jones, D. T & Ross, D. (2004). A máquina que mudou o mundo: baseado no estudo do Massachusetts Institute of Technology sobre o futuro do automóvel. Rio de Janeiro: Elsevier.

Ying, K. C. (2008). Minimizing earliness-tardiness penalties for common due date single-machine scheduling problems by a recovering beam search algorithm, Computers and industrial Engineering,

Zhou, H., Feng, Y. & Hang, L. (2011). The hybrid heuristic genetic algorithm for job shop scheduling. Computers & Industrial Engineering , 191-200.