Increased manufacturing performance in the light of the theory of constraints: the case of a mattress factory
DOI:
https://doi.org/10.14488/1676-1901.v17i1.2321Keywords:
Theory of constraints. Bottleneck. Continuous improvement. Mattress industry.Abstract
The Theory of Constraints (TOC) makes possible to identify, control and manage gaps in the best way possible at any productive system by using five steps to do the restrictions management. The goal of this work is to increase the productive process performance with the exclusion of gaps through the application of the Theory of Constraints and the guidelines of the focalization’s five steps in a mattress factory located at Rio Grande do Sul. The research was done with an exploratory objective and descriptive nature to the Theory of Constraints, action research with interventions and also other evaluation techniques, analysis and identification to the process improvement, where they show themselves as supporting tools. The results relate to the identification of gaps, gaps process notion and its elimination. With the TOC 1 (held in the packaging sector and review) the amount of parts per hour increased from 43 to 51 with the step 2, which is equivalent to 18,6%, and after in the step 4 from 51 to 72 parts, a 41% increase by the purchase of an automatic packing machine, also in this TOC was possible a reduction of employees from 5 to 3. With the TOC 2 (held in the assembly sector) the increase of the parts amount was from 59 to 71, about 25%, by the layout and production flow changes, counting with the employees reduction from 17 to 11 in the sector. With the results there was significant production gains, increasing by that this factory unit performance.Downloads
References
ANDRADE, E. L. Introdução a pesquisa operacional. Rio de Janeiro: LTC, 2014.
BLACKSTONE, John H. Theory of constraints : a status report. International Journal of Production Research, v. 39, n. 6, p.1053-1080, 2001. http://dx.doi.org/10.1080/00207540010028119
BOSCHETTO, S. N. LUDERS, R.; NEVES JR., F.; ARRUDA, L. V. R. Um modelo de otimização da operação de terminais petrolíferos usando a teoria das restrições como pré-processamento. Pesquisa Operacional, v. 29, n.1, p.1-21, 2009. http://dx.doi.org/10.1590/S0101-74382009000100001
BOYD, L.; GUPTA, M. Constraints management: what is the theory? International Journal of Operations & Production Management, v. 24, n. 4, p. 370-371, 2004. http://dx.doi.org/10.1108/01443570410524631
CALIA, R. C.; GUERRINI, F. M. Six Sigma project for scheduling software implementation. Production, v.15, n. 3, p. 322-333, 2005. http://dx.doi.org/10.1590/S0103-65132005000300004
CARVALHO, F. S. A ecoeficiência dos processos do sistema de gestão de uma fábrica de colchões e estofados baseado nos suas não conformidades: estudo de caso. 2011. 76f. Dissertação (Mestrado em Tecnologia Ambiental) - Universidade de Santa Cruz do Sul, 2011.
CHIAVENATO, I. Introdução a teoria geral da administração. 7. ed. Rio de Janeiro: Elseiver, 2003.
CONTADOR, José Celso (Coord.). et al. Gestão de Operações: a engenharia de produção a serviço da modernização da empresa. São Paulo: Edgar BlücherLTDA, 1998.
COSTER, I.; FOURNIE, X.; FAURE, C.; ZIANI, E.; NICOLAS, L.; SOUBEYRAND, B.; DAMME, P. V. Assessment of preparation time with fully-liquid versus non-fully liquid paediatric hexavalent vaccines - a time and motion study. Vaccine, v. 33, n. 32, p. 3976-3982, 2015. http://dx.doi.org/10.1016/j.vaccine.2015.06.030
COX III, J. F.; SPENCER, M. S. Manual da teoria das restrições. Porto Alegre: Bookman, 2002.
DALTON, Michael A. What's Constraining Your Innovation?, Research-Technology Management, v. 52, n. 5, p. 52-64, 2009.
GOLDRATT, E. M.; COX, J. A meta: um processo de melhoria contínua. 2. ed., rev. e ampl. São Paulo: Nobel, c2003.
GUPTA, Mahesh; KLINE, Joseph. Managing a community mental health agency: a theory of constraints based framework. Total Quality Management, v.19, n.3, p. 281-294, 2008.
GUPTA, Mahesh, et al. Improving the weakest link: a TOC-based framework for small businesses. Total Quality Management, v. 21, n. 8, p. 863-883, 2010. http://dx.doi.org/10.1080/14783360701601850
INMAN, R. A.; SALE, M. L.; GREEN JR, K. W. Analysis of the relationships among TOC use, TOC outcomes, and organizational performance. International Journal of Operations & Production Management, v. 29, n. 4, p. 341-356, 2009.
http://dx.doi.org/10.1108/01443570910945819
LACHTERMACHER, G. Pesquisa operacional na tomada de decisão. São Paulo: Pearson Prentice Hall, 2009.
LENORT, R.; KLEPEK, R.; SAMOLEJOVÁ, A. Heurisic algorithm for planning and scheduling of forged pieces heat treatment. Metalurgija, v. 51, n. 2, p. 225-228, 2012,
LOPETEGUI, M.; YEN, P.Y.; LAI, A.; JEFFRIES, J.; EMBI, P.; PAYNE, P. Time motion studies in healthcare: what are we talking about? Journal of Biomedical Informatics, v. 49, p. 292-299, 2014. http://dx.doi.org/10.1016/j.jbi.2014.02.017
MABIN, V. J.; BALDERSTONE, S. J. The Performance of the theory of constraints methodology: analysis and discussion of successful TOC applications. International Journal of Operations and Production Management, v. 23, n. 6, p. 568-595, 2003.
http://dx.doi.org/10.1108/01443570310476636
MOREIRA, D. A. Administração da produção e operações. São Paulo: Cengage Learning, 2013.
MOVERGS: Associação das Indústrias de Móveis do Estado do Rio Grande do Sul; Relatório setorial 2014, pólo moveleiro do Rio Grande do Sul. Disponível em: <http://www.movergs.com.br/img/arquivos/movergs/dados-movergs_77.pdf> Acesso em: 15-05-2015.
NAOR, M.; BERNARDES, E. S.; COMAN, A. Theory of constraints: is it a theory and a good one? International Journal of Production Research. v. 51, n. 2, p. 542–554, 2013. http://dx.doi.org/10.1080/00207543.2011.654137
OLIVEIRA, U. R.; MARINS, F. A. S.; ALMEIDA, D. A. Integrating operations management techniques and procedures: an application in a major Brazilian bank. Production, v. 20, n. 2, p. 237-250, 2010. http://dx.doi.org/10.1590/S0103-65132010005000008
PACHECO, D. A J. Integrando a estratégia de produção com a teoria das restrições, lean e seis sigma: uma abordagem metodológica (Dissertação de Mestrado). Universidade do Vale do Rio dos Sinos, São Leopoldo - RS. 2012.
PACHECO, D. A. J. Teoria das restrições, lean manufacturing e seis sigma: limites e possibilidades de integração. Production, v. 24, n. 4, p. 940-956, 2014. http://dx.doi.org/10.1590/S0103-65132014005000002
PERGHER, I.; RODRIGUES, L. H.; LACERDA, D. P. Theoretical discussion of the concept of wastes in the Toyota production system: introducing the throughput logic of the theory of constraints. Gestão e Produção, v. 18, n. 4, p. 673-686, 2011. http://dx.doi.org/10.1590/S0104-530X2011000400001
PRATES, C. C.; BANDEIRA, D. L. Aumento de eficiência por meio do mapeamento do fluxo de produção e aplicação do índice de rendimento operacional global no processo produtivo de uma empresa de componentes eletrônicos. Gestão e Produção. v.18, n.4, p. 705-718, 2011.http://dx.doi.org/10.1590/S0104-530X2011000400003
PRETORIUS, Pieter. Introducing in-between decision points to TOC’s five focusing steps. International Journal of Production Research, v. 52, n.2, p. 496-506, 2014. http://dx.doi.org/10.1080/00207543.2013.836612
QUELHAS, O.; BARCAUI, A. B. A teoria das restrições aplicada a gerência de projetos: uma introdução à corrente crítica. [2008]. Disponível em: . Acesso em: 11 nov. 2016.
RITZMAN, L. P.; KRAJEWSKI, L. J. Administração da produção e operações. São Paulo: Pearson Prentice Hall, 2004.
SANTOS, A. R. Metodologia científica: a construção do conhecimento. 4. Ed. Rio de Janeiro: DP&A, 2000.
SLACK, N.; CHAMBERS, S.; JOHNSTON, R. Administração da produção. 2. ed. São Paulo: Atlas, 2002.
SOBREIRO, V. A.; NAGANO, M. S. Um novo método heurístico para a otimização de mix de produção baseado na teoria das restrições e no problema da mochila. Revista Produção Online, v. 13, n.2 p. 520-543, 2013. http://dx.doi.org/10.14488/1676-1901.v13i2.1125
SOUZA, F. B. From the OPT to the theory of constraints: advances and myths. Production, v. 15, n. 2, p. 184-197, 2005. http://dx.doi.org/10.1590/S0103-65132005000200005
SUGAI, M. Avaliação do uso do MTM (Methods-Time Measurement) em uma empresa de metal-mecânica. 2003. 115 f. Dissertação de mestrado (Mestre em Engenharia Mecânica) - Faculdade de Engenharia Mecânica, Universidade Estadual de Campinas, Campinas, 2003.
THIOLLENT, M. J. M. Metodologia da pesquisa-ação. São Paulo: Cortez, 2008.
TOLEDO JUNIOR, I. F. B. Cronoanálise. 13. ed. Mogi das Cruzes: O&M Itys-Fides, 1995. 205 p. (Série Racionalização industrial)
WATSON, K. J.; BLACKSTONE, J. H.; GARDINER, S. C. The evolution of a management philosophy: the theory of constraints. Journal of Operations Management, n. 25, n. 2, p. 387-402, 2007. http://dx.doi.org/10.1016/j.jom.2006.04.004
WU, H. H.; LEE, A. H. I.; TSAI, T. P. A two-level replenishment frequency model for TOC supply chain replenishment systems under capacity constraint. Computers & Industrial Engineering, v. 72, p. 152-159, 2014. http://dx.doi.org/10.1016/j.cie.2014.03.006
WU, H. H.; CHEN, C. P.; TSAI, C. H.; TSAI, T. P. A study of an enhanced simulation model for TOC supply chain replenishment system under capacity constraint. Expert Systems with Applications, v. 37, n. 9, p. 6435-6440, 2010. http://dx.doi.org/10.1016/j.eswa.2010.02.074
ZIVALJEVIC, A. Theory of constraints - application in land transportation systems. Management of Environmental Quality: An International Journal, v. 26, n. 4, p. 505-517, 2015. http://dx.doi.org/10.1108/MEQ-07-2014-0110
Published
How to Cite
Issue
Section
License
The Journal reserves the right to make spelling and grammatical changes, aiming to keep a default language, respecting, however, the style of the authors.
The published work is responsibility of the (s) author (s), while the Revista Produção Online is only responsible for the evaluation of the paper. The Revista Produção Online is not responsible for any violations of Law No. 9.610 / 1998, the Copyright Act.
The journal allows the authors to keep the copyright of accepted articles, without restrictions
This work is licensed under a Creative Commons License .
