Avaliação do processo produtivo com Mapa de Fluxo de Valor: estudo de caso em uma pequena indústria

Abstract

This study addresses the increasing need for companies to update their management techniques and methodologies in a competitive globalized market. Lean Manufacturing emerges as an effective methodology to optimize processes, reduce costs, and add value to the final product, fulfilling customer needs with maximum quality and timely delivery. The study aims to evaluate the production process of a pet products factory using the Value Stream Mapping (VSM) tool to pinpoint improvement opportunities. A single case study was conducted, focusing on the production process of a specific pet product in a factory located in Cafelândia, São Paulo, Brazil. A qualitative approach, employing interviews, observation, and document analysis, enabled data collection and construction of the current state map. The VSM revealed significant losses, primarily related to excess intermediary stocks and motion waste due to inadequate production planning. Based on this analysis, a future state map was proposed, suggesting improvements grounded in Lean Manufacturing principles, aiming for a more efficient production flow and reduced lead time. This study concludes that VSM is an effective tool for identifying bottlenecks and waste, but its viability in environments lacking a lean culture is questionable. In such contexts, simpler tools may prove equally effective. The study highlights the importance of preparing the environment for lean implementation to achieve more significant results with VSM application.