Aplicação dos princípios do lean manufacturing em ambientes característicos de produção sob encomenda no segmento de papel e celulose na região de Araucária

Abstract

The objective of this coursework is studying and identifying the main difficulties of the make to order production - and, through the application of a visual management tool called PULSE (Lean principles), providing process improvements by aiming the waste elimination. A case study of a manufacturing and remanufacturing plant of a pulp, paper and energy industry will be performed, taking into account that it is a make to order production with a wide variety of products and low volume manufacturing. In this production system, every product is different and meet different specifications. Therefore, there is a high complexity level of distinct products and production processes. The consequence of this dynamic production is the difficulty for these companies to apply tools that support the production process, because, in general, they are organized based on mass assembly lines. Many of these tools are based on Lean manufacturing concepts, created from the Toyota Production System that addresses the reduction or elimination of activities that do not add value to processes. Among the variety of tools, the visual management allows an easy status analysis of the on going tasks. Besides that, it provides the production monitoring according to the priorities, making the decision process easier. For this coursework, it is proposed the PULSE tool of visual management that aims the lead-time reduction and the improvement of the efficiency of the product development and delivery. In order to accomplish the objectives proposed by this coursework, a research was performed, with a descriptive approach, in which processes and internal company data were analyzed, describing the hurdles and the proposed solutions. The result was the lead time reduction, the decrease of work hours and delivery times.