Proposta para redução de perdas de matéria prima através da aplicação de ferramentas de produção enxuta e de TQC: um estudo de caso em uma indústria de grande porte

Abstract

The Brazilian shoe industry is undergoing big changes to its production and organization, mainly because of competition from foreign products, especially from China. Brazilian industry is looking for ways to reduce costs, whilst still producing large quantities of quality products. In this situation Lean Manufacturing and Total Quality Control (TQC) emerge as strategic tools to increase efficiency and reduce costs. At present the goal of the industry is to decrease inefficiency in the use of raw materials, and therefore reduce the cost of application of the Lean Manufacturing and TQC tools. An investigation into what to do about surplus orders of raw materials in the shoe industry was done by analysis of their indicators, using a Pareto Analysis. This was used to investigate and discover problems with extra raw materials, and particularly which areas of the assembly line needed the extra material, therefore discovering the reasons why surplus raw materials were being ordered and used. An Ishikawa Daiagram is used to illustrate the research done using the Pareto Analysis. Afterwards an elaborate project of improvements was undertaken using Lean Manufacturing tools and TQC to obtain more control over the productive process on the assembly line, in order to reduce production losses and consequently reduce requests for raw materials.