Análise do sistema produtivo: Proposta de implementação do sistema de manufatura enxuta em uma empresa, do setor calçadista, no interior de São Paulo.

Abstract

The need for companies to reinvent themselves, finding and implementing lean production system methods, is increasing in the current business world, due to high competitiveness, globalization and the real world economic and social situations. Thus, this study aims to propose the implementation of Lean Manufacturing in a footwear industry company, an environment that is not so technologically developed yet, through the application of STP tools such as Value Stream Mapping, focusing the optimization of the production process, waste elimination, which doesn’t add value to the product, and ensuring stability for the company, both in production capacity and in quality. In this way, the work composes the analysis of the flowchart and the current VSM of the company, in order to find, within the production process, improvements and waste to be eliminated, in order to ensure a greater to ensure greater standardization and optimization of the organization, through the use of tools, creation of manuals, adoption of a culture of continuous improvement and opportunities for structural or process changes. In this way, the employee will have a better condition, ease and understanding of the role that he should perform in the work environment in addition to being aware and motivated. It is noted that, in a company that is over 60 years old and with a not so high level of standardization, there is some resistance to the implementation of changes, and the presence of production defects on the part of employees when performing their tasks. On the other hand, the market experience acquired by the organization is considerable, having a good relationship with suppliers and customers, and notions of how the market works and the productive process of the sector in which it operates. The present work is characterized by an applied nature, with a qualitative-quantitative problem situation and descriptive objectives, through action research procedures. Finally, the application of the pillars, programs, philosophies and tools of lean manufacturing, provided a considerable reduction in the lead time of the product, with a reduction of two manpower that executed unnecessary transports, a stage of production, of consumption of materials, of the number of defects and reworks, the time in stock that the finished product was left to be loaded onto the truck, and the level of stock that the company maintains, reducing by 7 days the time in which the leather is stopped inside the company, before starting the production process. Improvements were also noted in the setup and cycle times of some activities, such as the leather cutting step, which reduced the knife search time by 31.1% and the task execution time by 16 %, due to the employee training program.