Estrutura conceitual para implementação de práticas lean em ambientes engineer-to-order: desenvolvimento e avaliação de um framework

Abstract

This research presents the development of a conceptual framework for the implementation of lean practices in manufacturing environments with engineer-to-order (ETO) processes, where these companies face problems such as: long delivery times, pressure to reduce costs and the need to coordinate multiple production activities. The focus of this research is on manufacturing, since it is the phase where most waste and operational inefficiencies manifest themselves most clearly. In ETO manufacturing environments, where products are highly customized and processes are non-repetitive, waste often occurs due to the lack of synchronicity in the engineering, manufacturing and installation phases of the product. The identification and categorization of waste are crucial for the successful implementation of lean practices. Thus, the general objective of this dissertation was to develop a conceptual framework for the implementation of lean practices adapted to the manufacturing particularities of the ETO environment. The research was based on a systematic review of the literature, focusing on the concepts of Lean Manufacturing and their applications in ETO manufacturing environments. The methodology of this research initially involved a systematic review of the literature in databases such as Science Direct and Web of Science, covering the period from 2012 to 2024, in addition to additional searches through Google Scholar. Subsequently, the methodology was structured based on a hierarchy of: Phases, Stages and steps (represented by FTs). For analysis, case studies were conducted in two ETO companies, using questionnaires applied to Experts to assess the importance and benefits of FTs in the different Phases of the framework. Data analysis included the percentage distribution of responses and a comparison between companies, considering their cultural and operational particularities. The analysis of the collected data allowed the iterative construction of the proposed framework. This research reinforces the importance of adapting lean principles to the manufacturing specificities in companies with ETO processes, considering their particularities and limitations. Finally, this research contributed to the advancement of knowledge about the application of lean practices in ETO manufacturing environments, offering a conceptual framework that can be used as a guide for companies seeking to improve their efficiency and competitiveness in the manufacture of their products.