Proposta de aplicação da produção enxuta em uma malharia com produção sob encomenda

Abstract

The relentless search for continuous process improvement, cost reduction and total elimination of waste was evidenced with the expansion of lean thinking. However, unlike mass production, Make to Order manufacturing companies, which have common processes for a diversity of parts whose demand changes according to the customer's specifications, find it difficult to apply the conventional practices of lean manufacturing tools. In this context, the present work presents the applicability of lean manufacturing techniques, such as value stream mapping, 5W2H methodology, Scrum, Kanban, Kaizen, the 20 key points, 5S program, in a small knitting factory whose production typology fits the characteristics of Make to Order (MTO). Therefore, based on information collection from the internal production process through direct observation, informal interviews with the owner and employees, and analysis of company documents, a case study was developed that suited the reality of the company and has the possibility of be put into practice, providing greater visualization and understanding of the process by the team by mapping the value flow, as well as improving engagement and communication with the Scrum methodology, increasing motivation with the 20 key points questionnaires, and increasing productivity, reducing of risks and the search for improvement remains rooted in the organizational culture of knitting through the 5S program. Thus, enabling the achievement of the results expected by the owner, ensuring compliance with customer expectations and reducing complaints and waste.