The lean manufacturing system applied to an auto parts industry in the heavy vehicles segment

Carvalho Cleginaldo Pereira De Carvalho Cleginaldo Pereira De,Reis Bruno Dos Reis Bruno Dos

doi:10.30574/gjeta.2021.7.2.0067

Carvalho Cleginaldo Pereira De Carvalho Cleginaldo Pereira De, Reis Bruno Dos Reis Bruno Dos

Open Access

https://doi.org/10.30574/gjeta.2021.7.2.0067

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Abstract

This paper aims to demonstrate how the adoption of a continuous improvement program, based on lean manufacturing tools, can benefit the production of automotive filters for heavy vehicles, considering improved productivity and reduced operational waste, with a consequent increase in effectiveness and cost reduction. In this study we used the lean manufacturing tools, mainly kaizen and value stream mapping. During its development, the application of a kaizen project in a production line of automotive filters for heavy vehicles, aimed obtaining increased productivity and better distribution of physical space, through the reduction of rework time, reduction of downtime due to maintenance and reduction of setup time. The use of lean manufacturing tools, through the instruments presented in this study, guaranteed the viability of improvements in the productive sector. This work allowed the observation of a consistent improvement in production capacity, with productivity increase, through the improvement of the operational time and reduction of time of waste. The best distribution of physical space and the best arrangement of items used by the production process were also achieved through the consolidation of two production lines.

Highlights

Globalization, market growth, absorption of new production techniques, as well as constant changes in the world economic scenario and the need to remain competitive, have made companies seek ways to stand out positively and better meet their demands and the requests of their customers
Operation 3 (OP3) improvements Unification of drain and sensor squeezers Previously the operator used two different nut runners to perform the torque on the drain and sensor, according to Figure 6
The use of lean manufacturing tools, through the instruments presented in this study, guaranteed the viability of improvements in the production sector

Summary

Introduction

Globalization, market growth, absorption of new production techniques, as well as constant changes in the world economic scenario and the need to remain competitive, have made companies seek ways to stand out positively and better meet their demands and the requests of their customers. Even in situations of productive and financial success, large companies understand that they cannot cool their efforts and investments in continuous improvement. To this end, [1] defines that lean manufacturing (LM) concepts have proven to be efficient in several production units in response to the most diverse internal and external demands. [2] report that lean manufacturing contributes to activities governed by waste elimination and increased efficiency and productivity of industries. It was observed that the adoption of a continuous improvement program, based on lean manufacturing tools, could act to benefit the production of automotive filters for heavy vehicles, with improved productivity and reduction of operational waste, with a consequent increase in effectiveness and cost reduction.

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