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Aplicação De Metodologias Lean Numa Unidade Industrial Do Setor Da Indústria Panificadora: Estudo De Caso
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Recentemente, a filosofia Lean tem sido cada vez mais utilizada na maioria dos setores
industriais, pois, sendo, uma filosofia que procura identificar e reduzir os desperdícios, assentando numa ideologia de melhoria contínua, permite melhorar o posicionamento competitivo das empresas que a implementam. No entanto, na indústria panificadora a aplicação desta filosofia é ainda muito escassa, devido à maior dificuldade de implementação deste tipo de metodologias neste setor, em comparação com outros. Com os acontecimentos mais recentes, as empresas sentem cada vez maior necessidade de reduzir custos e desperdícios, sendo, consequentemente, mais comum e crucial a implementação de filosofias e métodos
diferentes, que sejam mais rentáveis e que permitam uma maior produtividade.
Nesse sentido, realizou-se um estudo numa fábrica da indústria panificadora, a Realbolo, onde se procurou reduzir desperdícios e melhorar a eficiência dos seus processos através da implementação de metodologias Lean. Assim sendo, iniciou-se o estudo com o mapeamento de todo o processo de produção recorrendo à ferramenta Value Stream Mapping (VSM). Posteriormente, com recurso a Gemba Walks foram identificados diversos problemas existentes na fábrica para os quais se identificaram as causas-raiz recorrendo à ferramenta Diagrama 5W e, consequentemente, desenvolvidas sugestões de melhoria para os mesmos.
Para além disso, foram também implementadas as ferramentas 5S,
Standard Work e Diagrama de Esparguete, possibilitando maior organização e padronização dos processos e diminuição de desperdícios. E, por fim, foram desenvolvidos VSM's de estado futuro de ambas as linhas, onde se sugere a implementação futura de um sistema que incorpore pull, com o intuito de diminuir o lead time do processo.
Recently, the Lean philosophy has been more often used in most industrial sectors, since being a philosophy that seeks to identify and reduce waste, based on a continuous im- provement ideology, it allows to improve the competitive positioning of companies that im- plement it. However, in the bakery industry, the application of this philosophy is still very scarce due to the greater difficulty in implementing this type of methodologies in this sector, compared to others. With the most recent events, companies increasingly feel the need to reduce costs and waste and, consequently, it is more common and crucial to implement different philosophies and methods, which are more profitable, and allow a higher productivity. In this sense, a study was conducted in a factory in the bakery industry, Realbolo, which sought to reduce waste and improve the efficiency of its processes through the implementa- tion of Lean methodologies. Therefore, the study began with the mapping of the entire pro- duction process using the Value Stream Mapping (VSM) tool. Subsequently, using Gemba Walks, several problems existing in the factory were identified for which the root causes were identified using the "5 Whys" Diagram tool and, consequently, suggestions for improvement were developed. In addition, the 5S, Standard Work and Spaghetti Diagram tools were also implement- ed, enabling greater organization and standardization of processes and reduction of waste. Finally, the future state VSM for both lines was developed, where is suggested a future im- plementation of a system that incorporates pull, to reduce the process lead time.
Recently, the Lean philosophy has been more often used in most industrial sectors, since being a philosophy that seeks to identify and reduce waste, based on a continuous im- provement ideology, it allows to improve the competitive positioning of companies that im- plement it. However, in the bakery industry, the application of this philosophy is still very scarce due to the greater difficulty in implementing this type of methodologies in this sector, compared to others. With the most recent events, companies increasingly feel the need to reduce costs and waste and, consequently, it is more common and crucial to implement different philosophies and methods, which are more profitable, and allow a higher productivity. In this sense, a study was conducted in a factory in the bakery industry, Realbolo, which sought to reduce waste and improve the efficiency of its processes through the implementa- tion of Lean methodologies. Therefore, the study began with the mapping of the entire pro- duction process using the Value Stream Mapping (VSM) tool. Subsequently, using Gemba Walks, several problems existing in the factory were identified for which the root causes were identified using the "5 Whys" Diagram tool and, consequently, suggestions for improvement were developed. In addition, the 5S, Standard Work and Spaghetti Diagram tools were also implement- ed, enabling greater organization and standardization of processes and reduction of waste. Finally, the future state VSM for both lines was developed, where is suggested a future im- plementation of a system that incorporates pull, to reduce the process lead time.
Descrição
Palavras-chave
Lean Indústria Panificadora VSM 5S Standard Work Diagrama de Esparguete