Proposal for the integration of lean manufacturing and theory of constraints techniques and approaches in reducing the lead time of an assembly line

Authors

  • Marcus Vinicius Puerta Maxion Structural Components, Cruzeiro, SP, Brasil / Universidade Estadual Paulista (UNESP), Guaratinguetá, SP, Brasil.
  • Bruno Chaves Franco Universidade Estadual Paulista (UNESP), Guaratinguetá, SP, Brasil.
  • Julio Cesar Melo Universidade Estadual Paulista (UNESP), Bauru, SP, Brasil. https://orcid.org/0000-0003-4743-1652
  • Jorge Muniz Junior Universidade Estadual Paulista (UNESP), Bauru, SP, Brasil. https://orcid.org/0000-0003-3496-0256

DOI:

https://doi.org/10.14488/1676-1901.v24i4.5144

Keywords:

Lean Manufacturing, Theory of Constraints, Integration, Continuous improvement, Lead Time, Assembly line, Supply, Material handling

Abstract

The large number of global competitors has led automotive industry to seek improvements in operational management. This paper presents a proposal for the integration of the techniques and approaches of Lean Manufacturing and Theory of Constraints, through a practical application, aiming to reduce the lead time of a chassis assembly line. In a first stage, the concepts and possibilities of integration of both theories were presented and, based on an initial diagnosis of the supply system, changes were proposed, in an evolutionary manner, in which improvements based on Lean Manufacturing were implemented in each round. experiment, culminating in the implementation of improvements based on the Theory of Constraints, integrating both concepts. The final result obtained corroborates the efficiency of integrating the two approaches to process improvement, which contributed to a reduction in supply cycle times of around 89% for the target cell studied, being superior to the result obtained using only one of the techniques, without the need for significant investments and/or expenses.

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Author Biographies

Marcus Vinicius Puerta, Maxion Structural Components, Cruzeiro, SP, Brasil / Universidade Estadual Paulista (UNESP), Guaratinguetá, SP, Brasil.

Engenheiro Mecânico (1999) e Pós Graduado em Qualidade e Produtividade (2003) pela UNIFEI - Universidade Federal de Itajubá, Mestre em Engenharia de Produção (2016) pela UNESP - Universidade Estadual Paulista "Júlio de Mesquita Filho". Experiência no desenvolvimento e implementação de projetos de melhoria, Gestão de Operações e Qualidade, trabalhando temas de Lean Manufacturing e TOC (Theory of Constraints) Transformação Digital, Supply Chain e Administração de Operações. 

Bruno Chaves Franco, Universidade Estadual Paulista (UNESP), Guaratinguetá, SP, Brasil.

Engenheiro de Produção Mecânica (2007) e Mestre (2011) pela UNESP - Universidade Estadual Paulista "Júlio de Mesquita Filho" e Doutorado Sanduíche (2014) em Engenharia de Produção pela Université de Nantes - França. Experiência no desenvolvimento e implementação de projetos de melhoria da experiência do cliente e eficiência operacional trabalhando com temas como: Excelência Operacional, Transformação Digital, Supply Chain, Lean, Business Analytics e Data Science.

Julio Cesar Melo, Universidade Estadual Paulista (UNESP), Bauru, SP, Brasil.

Mestre em Engenharia de Produção pela Faculdade de Engenharia da Universidade Estadual Paulista (UNESP) e doutorando pela Faculdade de Engenharia da Universidade Estadual Paulista (UNESP). Desde 2019, leciona nos cursos de Engenharia de Produção, Engenharia Mecânica, Engenharia Elétrica, Engenharia Civil, Administração e Sistemas de Informação. Tem experiência em Engenharia de Produção e Administração de Empresas, com ênfase em Planejamento e Controle da Produção, Qualidade, Logística, Gestão da Cadeia de Suprimentos, Gestão da Produção e Operações, Manufatura Enxuta, Economia, Administração de Empresas, Marketing e Gestão de Recursos Humanos.

Jorge Muniz Junior, Universidade Estadual Paulista (UNESP), Bauru, SP, Brasil.

Professor Associado na UNESP. Foi Coordenador do Mestrado Profissional em Engenharia de Produção (2013-2020), é Editor Associado da Revista Production. Possui doutorado em Engenharia pela UNESP, com tese premiada pela ABEPRO sobre Gestão do Conhecimento, e mestrado pela Escola Politécnica da USP em Engenharia de Produção. Atuou como executivo na Ford Motor Company e participa de grupo de pesquisa internacional em Sistemas Sociais e Manufatura Futura (Indústria 5.0) e Gestão do Conhecimento em Sistemas de Produção e Ensino e Treinanento de novas tecnologias.

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Published

2024-12-04

How to Cite

Puerta, M. V., Franco, B. C., Melo, J. C., & Muniz Junior, J. (2024). Proposal for the integration of lean manufacturing and theory of constraints techniques and approaches in reducing the lead time of an assembly line. Revista Produção Online, 24(4), 5144. https://doi.org/10.14488/1676-1901.v24i4.5144

Issue

Vol. 24 No. 4 (2024): fluxo contínuo

Section

Papers

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