The Journal of Lean Systems (JoLS) aims, through original and unpublished articles, at qualifying and giving broad visibility to scientific production in Lean System and correlated areas. Our work plan of the journal comprehends relevant actions to increase journal’s recognition in the International scientific community, hence, meeting the current criteria in Industrial/Production Engineering Committees. Furthermore, our editorial team prioritizes the open participation of authors of other institutions and fast evaluation of submitted articles, assuring a first decision within 30 days upon submission. Articles’ publication is quarterly and in electronic format. The Journal of Lean Systems publishes its articles quarterly in electronic format. To access the journal’s website, simply go to the following link: http://leansystem.ufsc.br/. Prof. Dr. Guilherme Luz Tortorella g.tortorella@ufsc.br Editor Universidade Federal de Santa Catarina (UFSC) Prof. Dr. Diego de Castro Fettermann d.fettermann@ufsc.br Co-Editor Universidade Federal de Santa Catarina (UFSC) Prof. Dr. Glauco Garcia Martins Pereira da Silva glauco.silva@ufsc.br Co-Editor Universidade Federal de Santa Catarina (UFSC)
The Journal reserves the right to make normative, spelling and grammatical changes in the published article, aiming at maintaining the proper standard of the language, while respecting the personal style of the authors. Author (s) are fully responsible for the published article. Journal of Lean Systems is not responsible for any violations of Copyright. Journal of Lean Systems allows the author to retain the copyright of articles accepted for publication without restriction. Plagiarism constitutes unethical behavior and is inconceivable. This journal reserves the right to use any methods of detecting plagiarism to analyze the submitted works. This journal is licensed under a Creative Commons License.
BPM and Lean to improve the production process of an engineer-to-order metalworking industry
The present article describes how the mapping of the production process of a metalworking industry was carried out and the results obtained through it, using BPM, BPMN, Bizagi, Lean, GUT Matrix, 5W2H, and Brainstorming. The objective of this work comprises presenting the stages of the company's process diagnosis, aimed at highlighting problems and analyzing their causes, proposing improvements in the production process to increase company productivity. Mapping a process focusing on improving activities and their flow is a crucial part of staying relevant in the metalworking sector. The proposed method for the study included the following stages: identification of process actors, training for actors, mapping of the production process, process analysis, prioritization of problems, and proposal of improvements. Through the analysis of the mapped process, it was found that, through the 11 actions developed in the improvement proposal, the company would be able to eliminate process waste, achieving better utilization of its production capacity. With the problems presented by the company, it is concluded that, among the developed actions, those focused on the company's information management would have greater relevance in process improvement.
Copyright (c) 2024 http://creativecommons.org/licenses/by-sa/4.0
Tendências de pesquisa em Construção Enxuta: uma revisão sistemática de literatura
The construction industry has a significant impact on a country’s economy. However, it faces challenges related to all three aspects of sustainability, particularly due to waste generation and inefficiencies. In this context, Lean Construction serves as a management philosophy that aims to reduce waste, enhance construction efficiency, and deliver high-quality products. Despite its benefits, uncertainties persist regarding the implementation of Lean principles and their interactions within the construction sector. The objective of this study is to analyze research trends related to Lean Construction through a systematic literature review (SLR) between 1992 and 2022. After applying filters, 215 out of 601 articles were selected for critical reading and content analysis. The SLR revealed valuable insights into these trends, including main researchers, research methods, and geographical regions. Additionally, it explored the primary tools used in construction, the interplay between Lean Construction and other approaches, and existing research gaps in the field.
Barriers to lean construction: a systematic literature review
Lean Construction (LC) is a philosophy aimed at enhancing process efficiency and reducing waste in the construction industry. LC emerged from applying and adapting Lean Manufacturing concepts to construction. The term LC gained prominence in 1992 following the publication of "Technical Report No. 72 – Application of the New Production Philosophy to Construction," by Lauri Koskela. Given that these concepts originated in manufacturing, certain characteristics of the construction industry can prevent their application, acting as barriers that hinder Lean Construction's implementation. Recognizing and identifying the difficulties associated with LC practice can serve as input for organizations to prepare themselves, thereby increasing the chances of successful LC implementation. In this context, the goal of this research was to identify barriers to LC mentioned in scientific articles since 2010. The methodology employed was the systematic literature review (SLR) technique, along with bibliometric data analysis. The SLR was conducted using the Scopus and Emerald databases. Sixty articles were selected in the SLR from which forty barriers to LC were extracted, in different countries and contexts, such as: difficulty in obtaining support and commitment from senior management, resistance to change by leadership, lack of good communication, unskilled labor, lack of knowledge about lean construction philosophy, among others.
Use of discrete event simulation and lean production in medical care analysis of a colonoscopy center
High-quality medical care has become imperative amid the COVID-19 pandemic. Advances in the development of computer simulation models to resolve issues in inefficient hospital services, especially with regard to the appropriate use of resources and reduction of waiting times, have an essential purpose. In this context, the objective of this research is to apply Discrete Event Simulation in a coloproctology care center, combined with the premises of Lean Production to highlight the “non-value-adding activities” of the procedural flow. The methodology used was modeling and simulation using real data. The object of study is a colonoscopy center located at the Hospital das Clínicas Samuel Libânio in Pouso Alegre, Minas Gerais, which provides services in the morning. As a result, an average value-adding percentage value of 28.24% in providing care was evidenced, which indicates inefficient operation due to the unsatisfactory use of medical and nursing professionals in patient care.
Melhora no índice de renovação de estoque
Uma indústria mecânica fornecedora para o setor de óleo e gás está enfrentando um problema relacionado ao aumento do volume de materiais e do custo médio de estoque, que gera gargalo nas áreas de armazenagem, custo de armazenagem em fornecedores externos e aumento do custo de manutenção de estoque. Com base nesse contexto, o objetivo deste trabalho é a melhora no índice de giro de estoque a partir da redução do volume de materiais e custo médio de estoque. Como método, utilizou-se o A3, congregando as seguintes ferramentas para chegar à solução do problema: Brainstorming com a equipe; ida ao Gemba; 5 Porquês para identificação da causa raiz; Diagrama Ishikawa; geração de Árvore de Causas; levantamento de Dados e Fatos; e cálculo do Indicador de Giro de Estoque. A implantação do plano de ação permitiu reverter a queda no índice de giro de estoque de 100% em 2019 para 87% em 2020 e 83% em 2021, voltando ao índice de 100% em 2022, garantindo menor tempo de permanência de materiais em estoque e melhorando a capacidade de renovação do armazém.
Copyright (c) 2023 http://creativecommons.org/licenses/by-sa/4.0
Redução de desperdícios de produtos “in natura”
The application of Lean tools makes it possible, among other things, to improve processes in general. However, before its application, the diagnosis of the situation in which the process or production system is found must be well listed. Lean as a Philosophy presents a number of benefits and has a recognized degree of applicability. In this case, the objective in question was to reduce the volume of "in natura" product wasted in the bottling line (production). In order to adjust the process related to item M150, a series of actions were established, which are described in the item “Action Plan”. After applying the aforementioned action plan, the partial results obtained were a 3% reduction in in natura product waste in the bottling stage (Jan/Apr 2023); creation of Standard Operating Procedure for line M1; mechanical improvement in the M1 filling machine (Poka-Yoke installation study); and, training with operators to identify bottlenecks in filling. In addition, a better allocation of inputs was noted in the product preparation phase.
The Lean Tools and Elements most used in Literature - Application of PROKNOW-C for Selection and Analysis of a Bibliographic Portfolio
Abstract: The purpose of this article is to identify Lean tools, techniques and practices used in the implementations of manufacturing organizations globally and to select the most used ones. To better illustrate the study, the methodology of bibliometric review was used, through the Knowledge Development Process-Constructivist (Proknow-C), encompassing three steps: selection of the portfolio of articles; bibliometric analysis and systemic analysis. The studied portfolio revealed that there are many Lean tools, practices and/or techniques used that are repeated in successful implementations. In total, 29 journals were reviewed and it was concluded that the elements: Total Quality Management, Training, 5S, Just-in-Time, Value Stream Mapping, Standardization, Types of waste, Ergonomics, Leadership and Team Development, Multifunctional teams stand out with the number of citations within the portfolio, having 50% representation in the portfolio, so future studies related to determining which Lean tools and techniques to apply in organizations will benefit from this research Keywords: Lean Manufaturing; Lean Implementation; Sytem; Model; Tool; Practices
Lean manufacturing diffusion analysis in the Itajaí Valley: A multiple case study in textile enterprises
Efficiency and competitiveness are constant for companies, especially in the textile industry. In this context, the application of lean manufacturing tools allows optimization of production processes and improvement in products quality, thus achieving positive outcomes. With that in mind, this study aims to diagnose and analyze the diffusion of lean manufacturing tools in the regional textile sector. It was conducted through multiple case studies in four textile companies from different segments in the Itajaí Valley region, all of which are large-scale enterprises (employing over 500 individuals). A questionnaire was responded by professionals operating at the tactical level, including managers, analysts, and coordinators. The results revealed that the surveyed companies possess knowledge about lean manufacturing tools, although not all tools are effectively utilized, showing there is still room for improvement. This way, future studies are necessary to amplify the sample, create and verify a model to maintain its implementation.
Technological roadmap integrating TPM and BIM in the management of building maintenance of federal universities
Planning of maintenance activities is the basis for the effective operation of service and restoration of public buildings. Currently, there are technological tools that can help to improve building management and maintenance, such as BIM (Building Information Modeling) and TPM (Total Productive Maintenance) the integration of these two concepts can bring significant gains to building maintenance. This work developed a technological roadmap integrating BIM and TPM, such as a tool to improve building maintenance management, focusing on reducing maintenance costs and prioritising preventive maintenance. This research has been developed through a systematic literature review, followed by the elaboration and application of the Roadmap, which evaluates after application in a pilot project at a federal university. The results have shown that the incorporation of the Roadmap into the routine of the maintenance sector provided higher control by the management, reducing corrective problems and extending the useful life of machines and equipment. The acceptance of the team involved in the process was positive, demonstrating the proposed project's potential. This study concludes that using the technological Roadmap, integrating BIM and TPM, proved promising and coherent with the expectations for building maintenance management. In addition, it offers a guide to help the application and use of the Roadmap in other institutions, with future perspectives to expand the impact of this approach on building maintenance management in different environments. Therefore, this research represents a relevant contribution to federal Universities, providing a technological tool to optimise building maintenance management.
The contribution of industry 4.0 to lean manufacturing
The term Industry 4.0 (I.4.0) has often been cited and is directly linked to the future of manufacturing activities, and within this context, interfaces with other concepts such as Lean Manufacturing occur, and the latter can benefit from the benefits generated by applying the principles, tools and techniques of I.4.0. The present work has the purpose of analyzing the influence of I.4.0 on Lean Manufacturing. The methodology used consists of a qualitative exploratory bibliographic study through the analysis and evaluation of papers, books and periodicals in a virtual environment, in the main databases (web of science, scopus, google scholar and emerald insight) and the results presented through the qualification the importance and applicability of the concepts of I.4.0 in Lean Manufacturing.
Diminuição do tempo de setup de uma linha de impressão de papelão ondulado
Uma empresa do setor de embalagens, produtora de caixas de papelão ondulado, está enfrentando um problema de redução de disponibilidade de máquina, em função de altos tempos de setup. Com base nesse contexto, o objetivo deste trabalho é a diminuição do tempo de setup de uma linha de impressão de papelão ondulado. Como método, utilizou-se o A3, congregando as seguintes ferramentas para chegar à solução do problema: brainstorming, 5 Porquês, diagrama Ishikawa; gráfico de Controle Estatístico de Processo (CEP); gráfico de espaguete, metodologia SMED, 5W2H, plano de inspeção de manutenção, treinamento com os operadores, metodologia 5S. A implantação do plano de ação permitiu diminuir o tempo de setup dos originais 10,2 minutos para 8,1 minutos, portanto, melhor do que a meta inicialmente definida de 9 minutos.
Lean Supply Chain Management: Insights from bibliometric analysis and literature review
The covid-19 pandemic has impacted many countries and with it arose a growing concern of organizations about the vulnerability and low resilience of global supply chains. The incorporation of lean manufacturing in the supply chains enables the systematic reduction of activities that do not add value in an organization and within a chain could improve business performance, which can be widely extended between areas. Thus, this paper aims to investigate the advancement of knowledge about the lean supply chain through bibliometric indicators of scientific production and literature review. Among the research results, the number of publications increased over the years (1996-2021), and the countries that published the most on the topic are Brazil (46 documents), Malaysia (42), and the United States of America (40). The most applied tool was the Value Stream Mapping (VSM). As for future research, there is a need to propose more applied and comprehensive research; study the impact of lean on the supply chain; evaluate the Lean Supply Chain implementation process, and study the relationship between sustainability and Lean Supply Chain Management.
Essa A3 estratégica tem como objetivo analisar o gap de representatividade acadêmica do GLean - Grupo de Estudos em Lean, da Universidade Federal de Santa Catarina, Brasil.
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Improvements through Lean Thinking: a case study in a health insurance company
The Brazilian private health system has experienced an increase in the costs of providing services due to the current economic and political crisis, amid the multiple impacts of COVID-19 pandemic. In this context, this study aims to identify the existing waste in two departments of a Health Plan Insurance Provider the (Audit and Customer Service & Authorization departments), as well as to propose improvements in the respective processes with the help of Lean Thinking. To do so, a descriptive case study was conducted as a research method, in which researchers gathered data and mapped processes through SIPOC matrices, followed by training and workshops to the employees. As a result, waiting and overprocessing were the most recurrent types of waste. Additionally, it was also observed that the employees’ training was essential for identifying critical types of waste and developing the SIPOC matrices. The proposal for improvements included digitization and changes in the parameterization of the systems, which positively reduce employee’s interference in the process hence avoiding mistakes and delays in the process. These actions will help reduce expenses with printed documents, reanalysis of procedures and errors in analyses.
Lean and the circular economy: A systematic literature review
Lean is a well-renowned strategy for increasing the value of products by minimizing waste. The circular economy is a new paradigm designed to mitigate environmental problems in production activities. Considering both perspectives, this article aims to understand how the application of lean can support the achievement of the circular economy. In order to attain this goal, the research presents a systematic literature review using the Scopus and Web of Science databases. Notably, the literature on the theme is still at an exploratory stage, the vast majority of research consisting of case studies. The main lean tools identified in the research are 5S and value stream mapping. The main circular practices, with lean support, are the Rs and ecodesign. The research proposes Circular Lean as a novel concept, one which merges some of the existing lean and circular economy principles. The main idea of this concept is the reutilization of material and energy, adding value and reducing waste within production processes and product life cycles.
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Production Engineering and Design Thinking, Do They Coexist? A Case Study Applied in the Elaboration of Layouts
Digital transformation is a process in which has influenced the way of buying and consuming products and services. In this sense, the retailer has a challenge, which is to attract customers to their physical establishments to offer a unique and personalized shopping experience. This work was developed in the commercial sector of a Commercial Exhibitors and Commercial Equipment Industry, located in the south of Brazil, in order to compare the lead time of the current layout design method in relation to the lead time of the process by applying Design Thinking to retail layout development. The methodology from the point of view of its nature is applied, in relation to its objectives was descriptive, regarding the approach: qualitative and as a case study. Based on the comparison between the current and future models, it was possible to reduce the lead time and increase the value added of 7.17% from the application of Design Thinking in the conduct of retail store layout projects.
Redução de divergências no recebimento de pedidos dos clientes
Uma empresa de cosméticos está enfrentando um problema relacionado a erros nos pedidos recebidos dos clientes, gerando divergências de informação com o sistema da empresa, ocasionando atraso e retrabalho do processamento de pedidos. Com base nesse contexto, o objetivo deste trabalho é a redução de divergências no recebimento de pedidos dos clientes. Como método, utilizou-se o A3, congregando as seguintes ferramentas para chegar à solução do problema: brainstorming com a equipe; 5 Porquês para identificação da causa raiz; Diagrama Ishikawa; e Carta de Controle. A implantação do plano de ação permitiu uma redução expressiva no indicador de pedidos rejeitados. Com isto, foi possível reduzir os impactos na cadeia para o processamento dos pedidos destes clientes.
PMOs - Diagnosis of the scope of project management offices for improvement purposes
Project Management Offices (PMOs) are essential mechanisms that facilitate their adaptation to the dynamic context of organizational organizations. Although there is a wealth of literature regarding the attributions of EGPs, it is not always an easy job to analyze the scope of application that exists now. This study aims to propose an instrument to identify the scope of EGPs' performance and, in this way, serve as a support for the diagnosis of office performance and, consequently, facilitate its maintenance and alignment with the goals of the organization to which it belongs. This research can be defined as applied, exploratory and with a qualitative approach. In turn, as a methodological approach, it was chosen as Design Science Research (DSR), a method oriented to the solution of practical problems. For the preparation of the instrument, 15 studies that typified EGPs according to their characteristics and attributions were selected. The questionnaire developed in this study was applied to an EGP in order to test its result. The EGP team responds to the proposed instrument, obtaining a view of the scope of action and its main characteristics. The instrument used to be useful in describing the status of the EGP's performance, with objectivity and practicality, highlighting areas that can be included or removed from the scope, or even improved, according to the organization's strategic objectives and the perception of managers responsible for it.
Escritórios de gerenciamento de projetos
Escopo de atuação dos escritórios de projetos
Copyright (c) 2022 Journal of Lean Systems
Use of Value Stream Mapping in a Dental Clinic: A Case Study
Society's search for well-being, self-esteem and quality of life has been increasing, increasing the demand for dental services. And this demand causes a need for companies to improve to meet and maintain the quality of care, making possible the loyalty and prospection of new patients. The objective of this research is to analyze the effects of the application of the VSM in the process of inferior protocol with immediate load. The methodology applied was a case study in a dentistry clinic of Vale dos Sinos - RS, from the mapping of the current state and proposed future state. As results, it was observed in the current state of the first stage a percentage of VA(Added Value) of 14.01% and lead time of 0.480 days and in the second stage of the process in a percentage of VAD AV of 5.35% and lead time of 2.76 days. In the developed proposal, following the principles of the Lean, so that the previously outsourced process can be carried out internally, it is suggested a percentage of VAD AV of 75.19% and lead time of 0.0895 days in the first step, and in the second one percentage of VAD AV of 42.60% and lead time of 2.08 days. This proposal requires an investment of R$ 9,783.00, that was analyzed with NPV and resulted in R$ 30,849.08, also presenting an IRR of 84%, making it viable.
Medida de retenção de clientes para estabilizar arrecadação da receita
Uma operadora de saúde está enfrentando um problema relacionado à alta variabilidade da sinistralidade do produto. À medida que a sinistralidade aumenta a arrecadação da receita cai, motivando o estudo do problema. Com base nesse contexto, o objetivo deste trabalho é estabelecer uma medida de retenção de clientes para estabilizar a arrecadação da receita. Como método, utilizou-se o A3, congregando as seguintes ferramentas para chegar à solução do problema: brainstorming com a equipe; 5 Porquês para identificação da causa raiz; Diagrama Ishikawa; e Carta de Controle. A implantação do plano de ação permitiu antecipar o contato com o cliente a fim de reverter inadimplências que poderiam resultar em cancelamentos impactando diretamente a arrecadação da receita. Observou-se que diminuindo o tempo para contatar os clientes inadimplentes, de 90 para 45 dias, as ações de reversão foram mais efetivas.
The precast construction industry and lean construction tools: flow-based management strategy
Abstract: The Toyota Production System (TPS) formulated the referential base for the elaboration of lean construction principles, called Lean Construction and organized by Lauri Koskela, in 1992. The application of lean production principles has become a major challenge for construction in the last decades, whose management parameter needs to be inserted in their industrial processes. The research proposes to articulate two objectives: first, to relate the competitive advantages of the construction of precast reinforced concrete, named in this study of precast industry constructs (PIC), as well as to identify which are the lean construction tools (LCT) incorporated to civil construction more exponents by the authors in their works. The second objective was to articulate a conceptual interrelationship of compatibility between the two factors: prefabricated construction and lean construction. The methodology was outlined by a qualitative and structured research through 178 publications, including books and scientific articles related to the studied themes. Data analysis established results that demonstrated a conceptual alignment between three constructs and three lean construction tools. Conclusively, the research found the convergence of the flow as a common element among the LCT, which allowed to base the lean construction processes on the strategy of flow-based management (FBM).
Discrete event simulation and lean production: quantification of waste in a pharmaceutical industry
Nowadays it is imperative that companies seek constant improvements in their operational performance so as not to become obsolete in relation to the new cutting edge trends of smart manufacturing or industry 4.0. In this context, it is noteworthy that manufacturing must occur in the presence of variability and uncertainty, and manufacturing systems must be complex, efficient and lean. Therefore, a conduct aimed at interventions focused on reducing waste in manufacturing and service operations are essential actions. A tool that can help in this purpose is the discrete event simulation (DES). In this context, the objective of this research is to apply DES and quantify the financial waste arising from non-value-adding activities. The object of study was a production line of a pharmaceutical industry and as a research method an approach was used combining modeling and simulation (quantitative) and case study (qualitative) methods. The software chosen was Flexsim®, a powerful simulation and process analysis tool that helps professionals in decision making. Finally, the results obtained through this research show the great financial waste in the analyzed assembly line. This impactful result on losses in the operation serves as a warning so that intervention measures are planned and executed to eliminate or mitigate the consequences of this waste.
Bibliometric survey on Lean Healthcare in Project Management
The hospital environment is very conducive to incorporate the Lean philosophy, as this organizations must provide quality services with a comprehensive resource restriction. Since some experts attribute many health services to inefficient work systems, these Lean tools have been associated with some complementary concepts, such as project management. Thus, it is necessary to level the literature to know the advances in the depth level of these tools. Therefore, this paper is intended to present an overview of the literature on Lean Healthcare aimed at Project Management. To achieve this goal, a bibliometric survey was first used using the PRISMA guide for reviews, analyzing the main institutions and countries involved with the publications. Then, a survey was done about the keywords used in the papers studied to identify the patterns present in the Lean Healthcare studies in Project Management. As results, it was possible to establish the universities that have the most impact on the production of papers in this theme, their countries of origin, as well as the characteristics of the papers present in the literature, concluding that there are still opportunities to drop further.
Introduction of the Heijunka methodology to improve the control and leveling of inventories of the operating system of a company in the metal-mechanical segment
Since competitiveness has become an increasingly noticed factor in the business scenario, it becomes essentially important for organizations to acquire new ways to manage the quality of products offered to customers. Thus, the objective of this research is to demonstrate the application of the concepts of Heijunka methodologies and the Kanban System as a method of leveling the stock level in a sidecar manufacturer, which for confidentiality purposes, will be considered in this article as Empresa Alfa, analyzing the benefits that the use of these tools brings to the management and stock control of projects, helping to ensure lean and flexible production. Thus, in order to highlight the topic analyzed with greater efficiency, a work was elaborated through the in loco study carried out in a systematic way based on the contents available in methods, techniques and procedures of a technical-scientific nature. Through this study, it was possible to verify the advantages and functionalities presented by the methodologies used, since the implementation of this instrument enabled a significant improvement in the inventory control of a pull production system. In addition, through the use of these tools, it was possible to show that the supply of products occurs in accordance with demand and in a standardized way, allowing the enterprise to carry out its activities in a lean and flexible manner, since it was possible to reduce the levels of stock considerably.
An analysis of quantitative techniques for lean production assessment
The implementation of lean production occurs through a continuous improvement process that requires constant monitoring. For this, assessment methods are used, and they are usually composed of quantitative techniques responsible for providing indicators that allow assessing the implementation stage of lean production. Given the diversity of techniques that have emerged in the literature, this article aims to analyze the quantitative techniques that have been applied, contributing to new research with a critical and up-to-date overview of the subject. For this purpose, we conducted a systematic literature review that selected 79 articles on the topic. From the analysis of the selected articles, ten techniques were identified, which were analyzed according to assessment requirements extracted from the same sample of articles. The results of the analysis showed that no technique was able to meet all requirements. However, the analysis allowed comparing the techniques in terms of fundamentals, the information they provide, and limitations. Thus, researchers and practitioners will benefit from a theoretical basis for choosing techniques, as well as they can obtain a sufficient foundation to outline future work.
The application of the Lean philosophy in agil project management - a case study
The use of Lean concepts in production is a well-known practice; however, its application in Project Management is a novelty that can bring competitive advantages for companies. More and more, companies have been adopting the agile project management as a strategy to increase their market competitiveness, so as to achieve good outcomes. In recent years, there has been an understanding that the use of better project management tactics is necessary, however that is no longer enough. It is also paramount to optimize the use of available resources in companies, to attain better results and cut down the waste to avoid higher investments. This is a study about the Lean concepts and their applicability in agile project management. Its aim is to analyze ways to insert Lean concepts in the agile project management in the expedition area of an aircraft engine repair company, through the use of kaizen philosophy, as to identify an opportunity of improvement, to map the current process, to develop solutions, to implement, to analyze results and, finally, to create a pattern. From the results generated, it is clear that the elimination of waste through methods established in the market such as lean manufacturing can, without a doubt, improve performance and ensure greater competitiveness for companies.
Lean manufacturing maturity level: a case-study applied in the Brazilian auto-parts industry
Lean Manufacturing known as Toyota Production System is a systematic method of waste reduction within a manufacturing system without sacrificing its productivity, assisting on the identification and steady elimination of waste. It has started in Japan and, besides the culture differences, it has arrived in Brazil and is being successfully used in some companies with engagement and commitment through the employees. As lean manufacturing is composed by many different tools that support the sustainability of the continuous improvement and considering the difficulty in assessing the evolution of this system through the operational maturity level, it is important to have a general overview of how methods are implemented and sustained by the organization in order to reach its targets. So far, the purpose of this article was the application of a business process maturity model questionnaire in a Brazilian auto-parts manufacturing company, specializing in interior electronics, which has fourteen methods related to its business system, then ordinate them to facilitate the gap's visualization between them and the company`s target. The first step was to understand each method, adapt the Business Process Maturity Model (BPMM) to evaluate the methods maturity, and finally propose a connection between them in order to observe the gaps and help the company to develop an action plan to guarantee that the sustainability of the implementation until all the methods reaches the highest lean maturity level.
Avaliação de produtividade de acordo com carga horária de trabalho para melhor definição de metas em laboratório metrológico de energia elétrica
Um laboratório de medidores de energia elétrica está enfrentando um problema relacionado à grande variabilidade em relação ao tempo de execução das atividades, podendo ocasionar um aumento ou redução de estrutura indevidamente, gerando custos e impacto negativo no clima organizacional. Com base nesse contexto, o objetivo deste trabalho é avaliar a produtividade de acordo com carga horária de trabalho para melhor definição de metas no laboratório metrológico de energia elétrica. Como método, utilizou-se o A3, congregando as seguintes ferramentas para chegar à solução do problema: brainstorming com a equipe; ida ao gemba (laboratório e RH); 5 Porquês para identificação da causa raiz; Diagrama Ishikawa; monitoramento dos tempos de execução das atividades ao longo de 3 meses, com uso de uma ferramenta computacional; e Carta de Controle. A implantação do plano de ação, permitiu chegar aos seguintes resultados e conclusões: em decorrência do brainstorming realizado com o RH foi identificada a necessidade de melhorias para a sistemática de análise do perfil psicológico e comportamental nas contratações e promoções e de continuidade do programa de desenvolvimento de líderes, que deverá abranger todos os cargos de liderança ligados às atividades do laboratório, podendo ser feito um trabalho especial com a supervisão para que a mesma possa ser mediadora entre o RH e a direção para questões ligadas ao corpo operacional. A melhoria da ferramenta computacional existente será de extrema importância para os recursos humanos do laboratório, pois impactará positivamente na minimização da dispersão dos tempos de execução dos serviços de avaliação técnica.
Use of the Workload Control (WLC) methodology to reduce the lead time of the machining process in a company in the manufacturing sector
The growing competitive pressure has driven the search for alternatives that provide both the reduction in delivery times and the mitigation of costs in all processes in the production chain. Thus, the objective of this research is to use the union of FMEA and Workload Control (WLC) methodologies in a company in the metalworking sector, which will be considered in this article as Empresa Alfa, identifying the problems that increase the lead-time of the process production, and with the help of the WLC methodology, analyze the workloads carried out on the production line so that it is possible to control production. In order to make the achievement visible to the company's employees, in this analysis, techniques were used that allowed a greater interaction with the daily routine of the organizational production line. Through this research, it was possible to analyze the benefits that the FMEA and WLC methodologies bring to the company in which it was implemented, since with a view of the possible failures identified through the FMEA methodology, the company can develop a corrective action plan to prevent against any listed failures. In addition, the use of the WLC methodology made it possible to view the workloads of employees, making it possible to view employees who were suffering from fatigue and who were working exhaustively.
Sustainability of the Brazil more productive program in the state of São Paulo
The objective of this study was to evaluate the sustainability of Lean Manufacturing initiatives implemented in small and medium-sized companies in the state of São Paulo conducted by the Brazil More Productive Program. The article proposes through the Theory of Organizational Knowledge Creation developed by Nonaka and Takeuchi a sustainability assessment model in the implementation of Lean Manufacturing, which is a challenge for companies that adopt the methodology in their production process. The method used for the analysis of the companies served by the program was through quantitative descriptive research. Based on bibliographic research on Lean Manufacturing, methodology implemented during the program, and on the Theory of Organizational Knowledge Creation, which covers the explicit and tacit knowledge important base of the Lean Manufacturing, a questionnaire was prepared with the purpose of analyzing the behavior of companies after participation in the program in relation to the sustainability of the initiatives. The answers from the companies with low continuity of the initiatives showed that tacit knowledge obtained a significantly lower result compared to explicit knowledge, mainly in the category of motivation and involvement of the people, requiring interference aimed at strengthening them to ensure sustainability of the initiatives implemented.