Lean Manufacturing: Systematic Layout Planning Application to an Assembly Line Layout of a Welding Industry
The purpose of this paper is to present the process of elaborating the layout of an assembly line of a welding industry using the principles of lean manufacturing as the main driver. The objective of this paper is relevant since the current layout of the assembly line causes non-productive times for operators, being related to the lean waste of unnecessary movements. The methodology used for the project development was Project-based Learning (PBL), which is an active way of learning focused on real problems. The process of selecting the methodology for layout planning was developed considering three criteria to evaluate the most relevant one for this paper's goal. As a result of this evaluation, Systematic Layout Planning was selected, and three steps were added to it – Value Stream Mapping for the current situation and after layout changed and the definition of lean tools and layout type. This inclusion was to consider lean manufacturing in the layout redesign of the industry. The layout change resulted in an increase in the value-adding time of operations carried out in the sector, reduction in movement times between previous and final assemblies, and in cost savings regarding the man-hour value of the employees, which can be invested in productive hours instead of movement times.
[1] L. Wilson, How to implement lean manufacturing. McGraw-Hill Education, 2010.
[2] J. Peinado, & A. R. Graeml, Administração da produção. Operações industriais e de serviços. Unicenp, 2007, pp. 201-202.
[3] B. Ngereja, B. Hussein, & B. Andersen, "Does Project-Based Learning (PBL) Promote Student Learning? A Performance Evaluation", in Education Sciences, vol. 10, 2020, pp. 330.
[4] P. A. Cauchick Miguel, A. Fleury, C. Mello, D. N. Nakano, & J. B. Turrioni, Metodologia de pesquisa em engenharia de produção e gestão de operações. Rio de Janeiro: 3rd ed., Ed. Elzevier, 2018.
[5] K. Hofmeister, QFD in the service environment. Quality Up, Costs Down: A manager's Guide to Taguchi Methods and QFD, 1995, pp. 57-78.
[6] R. Muther, & J. D. Wheeler, Planejamento sistemático e simplificado de layout. São Paulo: 2nd ed. vol. 1, Ed. IMAM, 2000.
[7] N. Slack, A. Brandon-Jones, & R. Johnston, Administração da Produção. São Paulo: 8th ed. Ed. Atlas, 2018.
[8] P. V. Favaretto, J. Kurek, A. P. Gomes, D. I. Caibre, & A. Pandolfo, “Projeto de layout industrial para uma empresa do ramo metal-mecânico com base nos princípios da Produção Enxuta”, in Revista Ciências Exatas e Naturais, vol. 13, 2011, pp. 45-71.
[9] A. L. D. Silva, A. F. & Rentes, “Um modelo de projeto de layout para ambientes job shop com alta variedade de peças baseado nos conceitos da produção enxuta”, in Gestão & Produção, vol. 19, 2012, pp. 531-541.
[10] R. Pache, V. B. Silva, L. A. dos Santos, E. Garlet, & L. P. Godoy, “Princípios da manufatura enxuta como proposta para arranjo físico na indústria de transformação de termoplásticos”, in Engevista, vol. 17, 2015, pp. 507-524.
[11] T. L. Urban, T. L. "Combining Qualitative and Quantitative Analyses In Facility", in Production and Inventory Management Journal, vol. 30, 1989, pp. 73.
[12] L. E. Assunpção, Estudo comparativo entre layouts sob a ótica dos indicadores da teoria das restrições com apoio de simulação de eventos discretos em empresa de alimentos. Bachelor's thesis, 2018.
[13] R. K. Yin, Estudo de Caso-: Planejamento e métodos. Ed. Bookman, 2015.
[14] S. Alex, C. A. Lokesh, & N. Ravikumar, "Space utilization improvement in CNC machining unit through lean layout", in Sastech Journal, vol. 9, 2010.
[15] S. M. Werner, F. A. Forcellini, & H. A. Ferenhof, Re-layout in a study environment to increase their capacity based on the SLP, in Journal of Lean Systems, vol. 3, 2018, pp. 87-101.
[16] M. Rother, & J. Shook. Learning to see: value stream mapping to add value and eliminate muda. 4th ed., Ed. Lean Enterprise Institute, 2009.
[17] R. M. Barnes. Estudo de movimentos e de tempos: projeto e medida do trabalho. Ed. Blucher, 1977.
[18] D. T. Matt, & E. Rauch, "Implementation of lean production in small sized enterprises", in Procedia Cirp, vol. 12, 2013, pp. 420-425.
[19] A. L. D. Silva. Desenvolvimento de um modelo de análise e projeto de layout industrial, em ambientes de alta variedade de peças, orientado para a produção enxuta. Doctoral dissertation, (Universidade de São Paulo), 2009.
[20] BNDES. (2020, July 06). Guia do financiamento (Web page). Retrieved from https://www.bndes.gov.br/wps/portal/site/home/financiamento/guia /quem-pode-ser-cliente/
[21] Ministério do Trabalho. “NR - 17 – Ergonomia”. in: SEGURANÇA e Medicina do Trabalho. São Paulo: 72 ed., 1990, pp.334- 337.
[1] L. Wilson, How to implement lean manufacturing. McGraw-Hill Education, 2010.
[2] J. Peinado, & A. R. Graeml, Administração da produção. Operações industriais e de serviços. Unicenp, 2007, pp. 201-202.
[3] B. Ngereja, B. Hussein, & B. Andersen, "Does Project-Based Learning (PBL) Promote Student Learning? A Performance Evaluation", in Education Sciences, vol. 10, 2020, pp. 330.
[4] P. A. Cauchick Miguel, A. Fleury, C. Mello, D. N. Nakano, & J. B. Turrioni, Metodologia de pesquisa em engenharia de produção e gestão de operações. Rio de Janeiro: 3rd ed., Ed. Elzevier, 2018.
[5] K. Hofmeister, QFD in the service environment. Quality Up, Costs Down: A manager's Guide to Taguchi Methods and QFD, 1995, pp. 57-78.
[6] R. Muther, & J. D. Wheeler, Planejamento sistemático e simplificado de layout. São Paulo: 2nd ed. vol. 1, Ed. IMAM, 2000.
[7] N. Slack, A. Brandon-Jones, & R. Johnston, Administração da Produção. São Paulo: 8th ed. Ed. Atlas, 2018.
[8] P. V. Favaretto, J. Kurek, A. P. Gomes, D. I. Caibre, & A. Pandolfo, “Projeto de layout industrial para uma empresa do ramo metal-mecânico com base nos princípios da Produção Enxuta”, in Revista Ciências Exatas e Naturais, vol. 13, 2011, pp. 45-71.
[9] A. L. D. Silva, A. F. & Rentes, “Um modelo de projeto de layout para ambientes job shop com alta variedade de peças baseado nos conceitos da produção enxuta”, in Gestão & Produção, vol. 19, 2012, pp. 531-541.
[10] R. Pache, V. B. Silva, L. A. dos Santos, E. Garlet, & L. P. Godoy, “Princípios da manufatura enxuta como proposta para arranjo físico na indústria de transformação de termoplásticos”, in Engevista, vol. 17, 2015, pp. 507-524.
[11] T. L. Urban, T. L. "Combining Qualitative and Quantitative Analyses In Facility", in Production and Inventory Management Journal, vol. 30, 1989, pp. 73.
[12] L. E. Assunpção, Estudo comparativo entre layouts sob a ótica dos indicadores da teoria das restrições com apoio de simulação de eventos discretos em empresa de alimentos. Bachelor's thesis, 2018.
[13] R. K. Yin, Estudo de Caso-: Planejamento e métodos. Ed. Bookman, 2015.
[14] S. Alex, C. A. Lokesh, & N. Ravikumar, "Space utilization improvement in CNC machining unit through lean layout", in Sastech Journal, vol. 9, 2010.
[15] S. M. Werner, F. A. Forcellini, & H. A. Ferenhof, Re-layout in a study environment to increase their capacity based on the SLP, in Journal of Lean Systems, vol. 3, 2018, pp. 87-101.
[16] M. Rother, & J. Shook. Learning to see: value stream mapping to add value and eliminate muda. 4th ed., Ed. Lean Enterprise Institute, 2009.
[17] R. M. Barnes. Estudo de movimentos e de tempos: projeto e medida do trabalho. Ed. Blucher, 1977.
[18] D. T. Matt, & E. Rauch, "Implementation of lean production in small sized enterprises", in Procedia Cirp, vol. 12, 2013, pp. 420-425.
[19] A. L. D. Silva. Desenvolvimento de um modelo de análise e projeto de layout industrial, em ambientes de alta variedade de peças, orientado para a produção enxuta. Doctoral dissertation, (Universidade de São Paulo), 2009.
[20] BNDES. (2020, July 06). Guia do financiamento (Web page). Retrieved from https://www.bndes.gov.br/wps/portal/site/home/financiamento/guia /quem-pode-ser-cliente/
[21] Ministério do Trabalho. “NR - 17 – Ergonomia”. in: SEGURANÇA e Medicina do Trabalho. São Paulo: 72 ed., 1990, pp.334- 337.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:80373", author = "Fernando Augusto Ullmann Tobe and Moacyr Amaral Domingues and Figueiredo and Stephany Rie Yamamoto Gushiken", title = "Lean Manufacturing: Systematic Layout Planning Application to an Assembly Line Layout of a Welding Industry", abstract = "The purpose of this paper is to present the process of elaborating the layout of an assembly line of a welding industry using the principles of lean manufacturing as the main driver. The objective of this paper is relevant since the current layout of the assembly line causes non-productive times for operators, being related to the lean waste of unnecessary movements. The methodology used for the project development was Project-based Learning (PBL), which is an active way of learning focused on real problems. The process of selecting the methodology for layout planning was developed considering three criteria to evaluate the most relevant one for this paper's goal. As a result of this evaluation, Systematic Layout Planning was selected, and three steps were added to it – Value Stream Mapping for the current situation and after layout changed and the definition of lean tools and layout type. This inclusion was to consider lean manufacturing in the layout redesign of the industry. The layout change resulted in an increase in the value-adding time of operations carried out in the sector, reduction in movement times between previous and final assemblies, and in cost savings regarding the man-hour value of the employees, which can be invested in productive hours instead of movement times.
", keywords = "Assembly line, layout, lean manufacturing, systematic layout planning. ", volume = "15", number = "6", pages = "174-10", }
