Aplicação da modularização nos sistemas de produção da indústria de calçados: o caso do setor de costura

Abstract

The footwear industry faces the challenge of dealing with a wide variety of products and production in small batches, which can lead to inefficiency and high costs. To solve this problem, the application of process modularization has proven to be a viable alternative. The modularization strategy can provide companies with various benefits, such as greater flexibility, agility and efficiency in the production system, which tends to allow companies to adapt quickly to changes in the products demanded by the market. In this context, the research proposed a new manufacturing method, based on the principles of modularization, considering the best use of the company's capital and knowledge assets. In order to achieve the stated objectives, the new method was applied, with logical steps to solve the problem, based on the principle of process modularization in a real environment. In the Design Science Research (DSR) methodology used to develop the method, a 6% reduction in production costs and a 47.5% reduction in process cycle time were measured between the current process and the proposed one. As a contribution, the study proposes the application of process modularization in order to reduce the complexity of production processes in the factory's production system. Finally, it is possible to suggest that the proposed method could be useful for solving cases similar to the one studied, both in companies in the footwear and textile industries.