Proposição de um método para aplicação integrada das técnicas de lean manufacturing e teoria das restrições em fornecedores da indústria automobilística

Abstract

In the global value chain (GVC), metal parts suppliers play a key role, as their operations directly affect the quality and efficiency of automakers' final assembly lines. The growing competitiveness of the sector requires companies to adopt new production and operations management strategies in order to improve their economic performance and increase their competitiveness in the market. The incorporation of methods, techniques and tools aimed at continuous improvement is essential, encompassing the identification and elimination of unnecessary processes, the reduction of inefficiencies and the lowering of operating costs, factors which ultimately contribute to increasing suppliers' profitability. Manufacturing excellence strategies play a crucial role in transforming production processes in factories, ensuring sustainable and profitable business growth. Therefore, this study aims, based on a review of existing literature, to develop and implement a method that integrates techniques and tools from Lean and the Theory of Constraints (TOC) in a production system of a supplier of components to automakers in the automotive sector. In addition, the research analyzes the effects of implementing the proposed method in the production flow of a supplier within the global value chain of the automotive sector. These effects were evaluated using economic and financial performance indicators, allowing for a comprehensive analysis of the results. The study mentions that the process function should not be interrupted, highlighting the importance of areas such as Production Planning and Control (PCP) and logistics. These areas, often seen as functional and little explored, can create barriers that interrupt the flow of the process. Integrated flow management is presented as an approach that seeks to break down these functional boundaries, promoting a continuous and efficient flow. This suggests that more effective coordination between the different areas can significantly improve the operation as a whole. The findings of this study show that the implementation of the proposed method generates positive and significant effects on the efficiency of the production flow. This finding not only validates the relevance of integrated Lean and TOC practices, but also highlights the importance of a systematic approach to continuous improvement in the automotive supply chain. In summary, the results obtained reinforce the need for suppliers to adopt innovative and effective practices, thus promoting a virtuous cycle of growth and competitiveness in the global market.