Implementação de ferramentas do lean manufacturing em processo de RTM-light em uma indústria de compósitos

Abstract

Efficient management of production processes has become increasingly necessary for companies seeking competitiveness and sustainability in the current market, underscoring the importance of lean methodologies in industrial transformation. The present study implemented Lean Manufacturing tools in the RTM-light (Resin Transfer Molding) sector of the composites unit at Máquinas Agrícolas Jacto S/A, with the objective of increasing productivity, improving efficiency, and eliminating waste. Challenges identified in the sector, such as workplace disorganization, layout inadequacies, and quality issues, served as motivation for this research. Methodologically, the study combined bibliographic research with action research, adopting 5S, Value Stream Mapping (VSM), operation balancing, and work standardization, utilizing time and motion studies and the Spaghetti Diagram for data collection and validation in two main products. As a direct consequence of the intervention, waste time was eliminated, and necessary time was reduced by 10.6 minutes (deflectors) and 34.5 minutes (reservoirs). The sector achieved an 18 percentage point increase in labor value availability, and the new layout resulted in an 82.51% reduction in the total distance traveled. Qualitatively, the 5S implementation promoted operator acculturation, ensuring renewed organization in the work areas. It is concluded that the structured application of lean tools validated the study's central hypothesis by promoting waste elimination and productivity growth, establishing a new efficiency standard and opening the path for future operational excellence projects within the company.