Lean thinking

: aplicação de técnicas de melhoria contínua em empresa de fabrico de couros artificiais

Abstract

Currently, global competition forces companies to produce with higher technical requirements, decreasing costs. In this context, the Lean philosophy aims to help businesses to enhance its value, reducing waste and associated costs. The company under study is dedicated to the production and sales of artificial leather especially for upholstery and footwear applications. The goal of the project is to implement Lean techniques in order to reduce the budget associated with the 2nd quality, particularly “rework”. At the beginning, it was developed an analysis of the situation of the company. Thus, it was used the tools like Ishikawa diagram, 5 W's, 5W's and H, Pareto diagram, as well as the analysis of internal non-conformities which lead to the identification of the primary waste in the organization: rework of nonconforming colors. The project was done based on the PDCA cycle (Plan-Do-Check-Act). In this sense, were planned and launched several initiatives such as the introduction of kanban to facilitate cutting of standard samples, poka-yoke system validation of color, and the most fundamental: sensitization to continuous improvement and the importance of the standard samples towards rework be avoided. After a one-year deployment, the main results are favorable to the application of Lean philosophy. There was a significant decrease in the number of "colored lacquers", and consequently the costs associated with rework. There was an increase in the number of standard samples, thus contributing to a more effective system of quality management. The organization noted the benefits of using Lean practices, and intends a full implementation of the technique "5 S's" in the future.

Date of Award	4 Mar 2015
Original language	Portuguese
Awarding Institution	Universidade Católica Portuguesa
Supervisor	Rita Ribeiro (Supervisor)