Aplicação do mapeamento do fluxo de valor para melhoria do fluxo de produção em uma linha de usinagem de eixos

Abstract

This Final Undergraduate Project aims to apply Value Stream Mapping (VSM) to the shaft machining line of an electric motor manufacturing company, identifying waste and proposing improvements based on Lean Manufacturing principles. The study was conducted as a case study with a quantitative approach, using direct observation on the shop floor, interviews with operators, analysis of technical documents, and time measurements of operations. The mapping of the current state revealed bottlenecks, long waiting times between operations, excessive distances in the layout (168 m), high lead time (21.6 h), and low value-added ratio (0.40%), characterizing a push flow with low efficiency. Based on this diagnosis, a future state map was developed, proposing the reorganization of the layout into manufacturing cells, reduction of cycle times and setups, elimination of intermediate inventories, implementation of continuous one-piece flow, and adoption of a pull production system. The estimated results indicate significant gains, including a 99.1% reduction in lead time (0.196 h), an increase in valueadded time to 28.87%, and a reduction of the physical path to 23.15 meters. The study confirms the effectiveness of VSM as a strategic tool for optimizing industrial processes, reinforcing its potential to support continuous improvement and enhance operational efficiency. [resumo fornecido pelo autor]