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Aplicação de metodologias Lean na redução de WIP numa fábrica de equipamentos para automação logística
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A presente dissertação foi elaborada no âmbito do estágio curricular desenvolvido na Körber
Supply Chain PT, S.A, empresa fabricante de soluções de automação logística, e tem como
objetivo quantificar e reduzir o Work in Progress (WIP) na área da logística interna recorrendo
a ferramentas Lean. A metodologia adotada foi a Model for Analysis of Process Improvement
and Control (MAPIC), que se destaca das metodologias tradicionais por incorporar uma
validação técnica e financeira das ações propostas previamente à sua implementação. Após a
deteção e análise de três problemas evidentes em processos desenvolvidos na Körber,
nomeadamente a danificação de materiais rececionados, existência de riscos ergonómicos e de
segurança e incorreta utilização do layout, identificou-se que a causa raiz transversal aos três
problemas é o excesso de WIP. Recorrendo a ferramentas Lean, como o Value Stream Mapping
(VSM), o waste map, o diagrama de Ishikawa e os 5 Porquês, foram formuladas e
implementadas ações de melhoria de modo a quantificar e reduzir o WIP, entre elas a
adaptação do layout, a normalização de processos e a diminuição do tempo de tarefas. Os
resultados demonstram uma redução de 60,6% do WIP (de 76,77 m² para 46,5 m²), um
aumento de espaço disponível para receção de material de 17,28 m² para 49,20 m². Além disso,
denotou-se também um aumento da classificação de 5S na zona da logística interna e um
aumento de eficiência de 39,75%. A validação da implementação das ações demonstrou que as
ferramentas Lean utilizadas resultaram num impacto significativo na melhoria contínua na área
da logística interna da Körber.
This dissertation was developed within the scope of the curricular internship carried out at Körber Supply Chain PT, S.A., a company that manufactures logistics automation solutions, and aims to quantify and reduce Work in Progress (WIP) in the internal logistics area using Lean tools. The methodology adopted was the Model for Analysis of Process Improvement and Control (MAPIC), which stands out from traditional methodologies by incorporating a technical and financial validation of the proposed actions prior to their implementation. After the identification and analysis of three evident problems in processes carried out at Körber, namely the damage of received materials, the existence of ergonomic and safety risks, and the incorrect use of the layout, it was found that the root cause common to all three problems was the excess of WIP. Using Lean tools such as Value Stream Mapping (VSM), the waste map, the Ishikawa diagram and the 5 Whys, improvement actions were formulated and implemented to quantify and reduce WIP, including layout adaptation, process standardization and the reduction of task time. The results show a 60.6% reduction in WIP (from 76.77 m² to 46.5 m²), as well as an increase in the available space for material reception from 17.28 m² to 49.20 m². In addition, there was also an increase in the 5S score in the internal logistics area and a 39.75% increase in efficiency. The validation of the implementation of the actions demonstrated that the Lean tools used had a significant impact on continuous improvement in Körber’s internal logistics area.
This dissertation was developed within the scope of the curricular internship carried out at Körber Supply Chain PT, S.A., a company that manufactures logistics automation solutions, and aims to quantify and reduce Work in Progress (WIP) in the internal logistics area using Lean tools. The methodology adopted was the Model for Analysis of Process Improvement and Control (MAPIC), which stands out from traditional methodologies by incorporating a technical and financial validation of the proposed actions prior to their implementation. After the identification and analysis of three evident problems in processes carried out at Körber, namely the damage of received materials, the existence of ergonomic and safety risks, and the incorrect use of the layout, it was found that the root cause common to all three problems was the excess of WIP. Using Lean tools such as Value Stream Mapping (VSM), the waste map, the Ishikawa diagram and the 5 Whys, improvement actions were formulated and implemented to quantify and reduce WIP, including layout adaptation, process standardization and the reduction of task time. The results show a 60.6% reduction in WIP (from 76.77 m² to 46.5 m²), as well as an increase in the available space for material reception from 17.28 m² to 49.20 m². In addition, there was also an increase in the 5S score in the internal logistics area and a 39.75% increase in efficiency. The validation of the implementation of the actions demonstrated that the Lean tools used had a significant impact on continuous improvement in Körber’s internal logistics area.
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Lean Tools WIP Continuous Improvement MAPIC Ferramentas Lean