Desenvolvimento de um processo de manufatura enxuto para ambientes Engineer-to-Order (ETO)

Abstract

The increasing competitiveness of industrial environments, especially those operating under the Engineer-to-order (ETO) logic, requires companies to develop manufacturing processes capable of dealing with high variability, strong cross-functional integration, and a high level of operational coordination. In this context, this dissertation aimed to develop a manufacturing process by integrating lean concepts and practices in high-customization environments, through the application of the action research method in a capital goods manufacturing company. The Production Function Mechanism (PFM) and Value Stream Mapping (VSM) were adopted as conceptual and practical foundations and applied to a pilot manufacturing sector - welding. The specific objectives were to identify prevalent losses and waste in high-customization environments, analyze the role of advanced technologies in production flows, and map the company's production flow, identifying its interrelationships and opportunities for improvement. The application of the method enabled a systemic visualization of the production flow and the interfaces between engineering, Production Planning and Control (PPC), and manufacturing, highlighting issues such as lack of standardization, high levels of Work-in-Process (WIP), and low operational predictability. Based on the diagnosis, improvement actions were structured and implemented on a pilot scale, resulting in advances in order prioritization, lead time reduction, and improved alignment between planning and execution. The results demonstrate that the development of a flow-oriented manufacturing process supported by lean practices significantly contributes to improved operational performance in ETO environments, supporting managerial decision-making, process standardization, and strengthened cross-functional integration. [resumo fornecido pelo autor]