Maintenance’s Value Stream Mapping as a useful tool for the implementation of Lean Maintenance: case study in an injection’s sector of a thermoplastics company

Danilo Ribamar Sá Ribeiro, Fernando Antônio Forcellini, Milton Pereira

Abstract


Value Stream Mapping is a tool that support in the introduction and use of lean thinking through the identification of value creation. In addition to Production, this tool can be applied to other areas, such as in the Maintenance’s process. The use of the tool in Maintenance is known as MFVM. This should be one of the first tools to be used in the implementation process of Lean Maintenance, since it is a technique of mapping the flows of materials and information that trigger the processes that allow to perform the Maintenance. Therefore, the main objective of this work is to apply the MFVM’s tool in a thermoplastic company. In order to reach the proposed objective, we searched the literature through an exploratory research, which works have already used the MFV tool in Maintenance. Based on the portfolio generated, the tool was applied in practice. The application of MFVM, a tool that is part of the Lean Maintenance approach, identified wastage within the planned and corrective maintenance process in the company’s Injection sector. This research shows that MFVM is a powerful tool for implementing Lean Maintenance and allows each industry to continuously understand and improve its lean understanding in Maintenance.

Keywords


Value Stream Mapping – VSM; Value Stream Mapping in Maintenance – VSMM; Lean Maintenance

References


Abdulmalek, F. A., & Rajgopal, J. (2007). Analyzing the benefits of lean manufacturing and value stream mapping via simulation: A process sector case study. International Journal of production economics, 107(1), 223-236. https://doi.org/10.1016/j.ijpe.2006.09.009

Araújo, S. M. F. (2010). Implementação de um Sistema de Manutenção Lean na SNA Europe [Industries] S.A. Dissertação de Mestrado (Mestrado Integrado em Engenharia Metalúrgica e de Materiais) – Faculdade de Engenharia da Universidade do Porto, Portugal.

Barbosa, N. L., Castro, S. I. M., Elias, S. J. B. & Tubino, D. F. (2011). Análise dos Processos de Manutenção Preventiva de Elevadores: Uma Abordagem Lean. Anais do XXXI Encontro Nacional de Engenharia de Produção – ENEGEP. Belo Horizonte – Minas Gerais.

Bonamigo, A, Paimell, F. A. & Arbugeri, L. A. (2017). Implementação do VSM por meio do Conceito Toyota Kata. Anais do VII Congresso Brasileiro de Engenharia de Produção – CONBEPRO, Ponta Grossa – Paraná.

Brown, A., Amundson, J., & Badurdeen, F. (2014). Sustainable value stream mapping (Sus-VSM) in different manufacturing system configurations: application case studies. Journal of Cleaner Production, 85, 164-179. https://doi.org/10.1016/j.jclepro.2014.05.101

Dal Forno, A. J., Pereira, F. A., Forcellini, F. A., & Kipper, L. M. (2014). Value Stream Mapping: a study about the problems and challenges found in the literature from the past 15 years about application of Lean tools. The International Journal of Advanced Manufacturing Technology, v. 72, n. 5-8, p. 779-790. https://doi.org/10.1007/s00170-014-5712-z

Elias, S. J. B., Oliveira, M., & Tubino, D. F. (2011). Mapeamento do fluxo de valor: um estudo de caso em uma indústria de gesso. Revista ADMpg Gestão Estratégica, 4(1).

Fourie, C. J., & Umeh, N. E. (2017). Application of lean tools in the supply chain of a maintenance environment. South African Journal of Industrial Engineering, 28(1), 176-189. http://dx.doi.org/10.7166/28-1-1507

Funegan, T. & Humphries, J. (2006). Maintenance gets Lean: Synergies for step change. Industrial Engineer, 38(10), 26-32.

Gonçalves Filho, M., Da Silva, F. A., Machado, L., Oliveira, R.I., Silva, R. G., Santos, N. C. & Campos, F. C. (2015). Revisão Bibliográfica da Manutenção em Ambiente de Manufatura Enxuta. Revista Espacios. 36(07).

Jahanbakhsh, M., Moghaddam, N. & Samaie, H. M. (2013). Lean maintenance (case study: Teen Dairy Industry Co.). International Research Journal of Applied and Basic Sciences, 4, 2033–2040.

Jasiulewicz-Kaczmarek, M. (2013). Sustainability: Orientation in maintenance management—Theoretical background. In EcoProduction and Logistics (pp. 117-134). Springer, Berlin, Heidelberg. https://doi.org/10.1007/978-3-642-23553-5_8

Kannan, S., Li, Y., Ahmed, N., & El-Akkad, Z. (2007). Developing a maintenance value stream map. In Institute of Industrial Engineers, Technical Societies and Divisions Lean Conference Proceedings.

Kardec, A. & Nascif, J. (2012). Manutenção Função Estratégica (4ª Ed.). Editora Quality Mark, Rio de Janeiro, Coleção Manutenção, Abraman.

Levitt, J. (2008). Lean maintenance. New York, NY: Industrial press.

Mostafa, S., Dumrak, J. & Soltan, H. (2015). Lean maintenance roadmap. Proceedings of 2nd International Materials, Industrial, and Manufacturing Engineering Conference, MIMEC2015, Bali, Indonesia.

Mostafa, S., Lee, S. H., Dumrak, J., Chileshe, N., & Soltan, H. (2015). Lean thinking for a maintenance process. Production & Manufacturing Research, 3(1), 236-272. https://doi.org/10.1080/21693277.2015.1074124

Nunes, M. A. M. (2013). Aplicação dos Princípios da Manutenção Lean na Indústria Farmacêutica. Dissertação de Mestrado (Mestrado em Engenharia Mecânica) – Instituto Superior de Engenharia de Lisboa, Lisboa, Portugal.

Pinto, J. P. (2009). Pensamento Lean: A filosofia das organizações vencedoras. Biblioteca Indústria & Serviços: Lidel-edições técnicas.

Ribeiro, D. R. S. & Forcellini, F. A. (2017). Implementação de Lean Maintenance em processos de manufatura: Uma Revisão Bibliográfica Sistemática. Anais do VII Congresso de Sistemas Lean, Niterói, Brasil.

Ribeiro, D. R. S. (2017). Sistemática de implementação de Lean Maintenance para processos de manufatura com base na Abordagem Toyota Kata. Dissertação de Mestrado em Engenharia Mecânica da Universidade Federal de Santa Catarina, 178p. Florianópolis, Santa Catarina. 2017.

Rother, M., & Harris, R. (2002). Criando fluxo contínuo. São Paulo: Lean Institute Brasil.

Rother, M & Shook, J. (2003). Aprendendo a Enxegar: mapeando o fluxo de valor para agregar valor e eliminar o desperdício. São Paulo: Lean Institute Brasil.

Salgado, E. G., Mello, C. H. P., Silva, C. E. S. D., Oliveira, E. D. S., & Almeida, D. A. D. (2009). Análise da aplicação do mapeamento do fluxo de valor na identificação de desperdícios do processo de desenvolvimento de produtos. Gestão e Produção, 16(3), 344-356.

Santos, L. C., Gohr, C. F., & dos Santos, E. J. (2012). Aplicação do mapeamento do fluxo de valor para a implantação da produção enxuta na fabricação de fios de cobre. Revista Gestão Industrial, 7(4). https://doi.org/10.3895/S1808-04482011000400006

Sawhney, R., Kannan, S., & Li, X. (2009). Developing a value stream map to evaluate breakdown maintenance operations. International Journal of Industrial and Systems Engineering, 4(3), 229-240.

Sembiring, N., & Nasution, A. H. (2018, February). Machine Maintenance Scheduling with Reliability Engineering Method and Maintenance Value Stream Mapping. In IOP Conference Series: Materials Science and Engineering (Vol. 306, No. 1, p. 012095). IOP Publishing.

Sembiring, N., Panjaitan, N., & Angelita, S. (2018, February). Design of preventive maintenance system using the reliability engineering and maintenance value stream mapping methods in PT. XYZ. In IOP Conference Series: Materials Science and Engineering (Vol. 309, No. 1, p. 012128). IOP Publishing.

Smith, R., & Hawkins, B. (2004). Lean maintenance: reduce costs, improve quality, and increase market share. Elsevier.

Stadnicka, D., & Antonelli, D. (2015). Application of value stream mapping and possibilities of manufacturing processes simulations in automotive. FME Transactions, 43(4), 279-286.

Stadnicka, D., & Ratnayake, R. C. (2017). Enhancing Aircraft Maintenance Services: A VSM Based Case Study. Procedia Engineering, 182, 665-672.

Tapping, D., Luyster, T., & Shuker, T. (2002). Value stream management: Eight steps to planning, mapping, and sustaining lean improvements. Productivity Press.

Thiruvengadam, A. (2009). A practical method for assessing maintenance factors using a value stream maintenance map(Doctoral dissertation, Wichita State University).

Wenchi, S., Wang, J., Wang, X., & Chong, H. Y. (2015, September). An application of value stream mapping for turnaround maintenance in oil and gas industry: Case study and lessions learned. Proceedings of 31st Annual ARCOM Conference (pp. 7-9).

Wiegand, B., Langmaack, R., & Baumgarten, T. (2007). Lean Maintenance System Zero Maintenance Time–Full Added Value Workbook. Lean Institute, Portsmouth USA.

Womack, J.P. & Jones, D. T. (2004). A mentalidade enxuta nas empresas – Lean Thinking – Elimine desperdícios e crie riqueza. Ed. Elsevier, Rio de Janeiro.


Refbacks

  • There are currently no refbacks.


_________________________________________________________

Licença Creative Commons
This journal is licenced under a Creative Commons LicenseCreative Commons - Atribuição-CompartilhaIgual 4.0 Internacional.

Contact: lean@contato.ufsc.br
Tel: +554837217062

EPS - Departamento de Engenharia de Produção e Sistemas

CTC - Centro Tecnológico

UFSC - Universidade Federal de Santa Catarina

Caixa Postal 476 - Campus Universitário - Trindade