Lean Manufacturing aplicado à otimização do layout fabril na montagem de tubulações em pulverizadores autopropelidos

Abstract

The industry has been increasingly charged for productivity, and the Lean Manufacturing ideology has proven to be an essential tool to reach the productive potential that the company can develop, as it impacts both employees and the company. The main objective of this work was to apply Lean concepts and tools in the plumbing assembly process of a self-propelled sprayer, identifying waste, activities that do not add value using lean production tools, as well as presenting a new layout configuration that enables optimization of the company's production potential. The research is of a quantitative nature with data collected in 2020, before the improvements be implemented and in 2022, after the improvements were implemented in a factory of agricultural machinery in the state of Goiás. For synthesis and analysis of the data, lean manufacturing tools were used, to identify which activities had added value and which did not. Also, the Spaghetti Diagram was used to design a new layout to minimize wasted time in moving materials and people. As a result, it can be seen that there was a potential reduction of 74% in the time of activities that do not add value and are unnecessary in the plumbing assembly process of the self-propelled sprayer solution system, which represents approximately a 15% reduction in production cycle and consequently potential reduction of resources in production depending on how many cycles are needed in the day. There was also a significant gain with the 69% reduction in handling activities that do not add value and may even reduce operator fatigue. It is important to mention that a strong and shared organizational culture is the key to the success of lean production and in this study, the participation of operators in layout change proposals was essential. As a result, the implementation of the changes took place without resistance and everyone felt part of the transformation, being Engineers, technicians and operators involved in the action as agents of change to improve the workstation.