Aplicação de Lean Manufacturing na redução de desperdícios no processo de reparação de motores de tração de uma empresa de logística ferroviária do Paraná

Abstract

The growth of rail freight transport has driven companies in the sector to seek the improvement of the availability of assets and the reduction of wastes in their processes, to become more competitive when compared to the road modal. With the objective of reducing some of these wastes, the present work applied the principles and tools of Lean Manufacturing at the traction motor repair processes in a logistics company. Based on these principles and using the DMAIC methodology, the processes were filmed and analyzed. With that, we sought to establish the value stream maps of the current and future state, in addition to proposing, based on these maps, a new factory layout and quick improvement actions. The surveyed results indicate a high rate of waste, mainly due to unnecessary movements. Only 20% of the time spent on maintenance was dedicated to activities that add value to the process. Quick wins were implemented to reduce wastes with unnecessary movements and provided gains of up to half an hour a day with washing activities, with low costs of implementation, just reducing these unnecessary movements. Finally, the new layout provided a better organization of the material flow inside the plant, through pull production systems, kanban boards and the reduction of the distance covered during the process.