Identificação e classificação de riscos na implantação da produção enxuta
Identifying and classifying the risks involved in the process of implementing lean production
Marodin, Giuliano Almeida; Saurin, Tarcisio Abreu; Caten, Carla Schwengber ten
http://dx.doi.org/10.1590/0103-6513.033011
Production, vol.25, n4, p.911-925, 2015
Resumo
O processo de implantação de sistemas de produção enxuta é complexo, demorado e sujeito a uma série de riscos. Este artigo tem como objetivo identificar e classificar os riscos presentes na implantação da produção enxuta (IPE). As quatro etapas da pesquisa foram: (i) revisão de literatura para identificação de riscos à IPE; (ii) desenvolvimento e aplicação de um questionário a 57 respondentes, que avaliou as percepções acerca da probabilidade de ocorrência e impacto de cada risco apontado pela literatura; (iii) análise dos resultados do questionário, que permitiu a classificação dos riscos por meio de uma análise fatorial exploratória; (iv) estudo de caso para aprofundar a compreensão das relações entre os riscos em uma empresa na qual trabalhavam três respondentes da survey. Quatorze riscos à IPE foram identificados e classificados em três grupos: (i) riscos associados ao papel das áreas de apoio; (ii) riscos associados ao papel da alta e média gerência; e (iii) riscos associados ao papel dos níveis operacionais. Uma vez que os riscos dentro de cada grupo são fortemente inter-relacionados, essa classificação pode contribuir para o planejamento e implantação de ações de controle destes.
Palavras-chave
Produção Enxuta. Gestão de riscos. Análise fatorial exploratória.
Abstract
The process of implementing lean production (LP) is complex, slow, and subject to several risks. This article aims at identifying and classifying the risks involved in the LP implementation process. The study was undertaken in four stages: (i) a literature review to identify the risks; (ii) the design and application of a questionnaire, answered by 57 respondents, to assess their perceptions on the probability of occurrence and impact of the risks identified from the literature review; (iii) analysis of the results of the questionnaire, which allowed for classification of the risks based on an exploratory factor analysis; and (iv) a case study, to gain an understanding of the relationships among the risks, performed at a company for which three respondents of the survey worked. Fourteen risks were identified and then classified in three groups: (i) risks associated with the role of support areas; (ii) risks associated with the roles of the top management and middle management; and (iii) risks associated with the role of the operational level. Because the risks within each group are strongly interrelated, this classification can contribute to improving the lean implementation strategies by managing the risks.
Keywords
Lean Production. Risk management. Exploratory factor analysis.
References
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Bateman, N., & David, A. (2002). Process improvement programmes: a model for assessing sustainability. International Journal of Operations & Production Management, 22(5), 515-526. http://dx.doi.org/10.1108/01443570210425156.
Bayo-Moriones, A., Bello-Pintado, A., & Merino-Díaz-De-Cerio, J. (2008). The role of organizational context and infrastructure practices in JIT implementation. International Journal of Operations & Production Management, 28(11), 1042-1066. http://dx.doi.org/10.1108/01443570810910188.
Bayou, M. E., & Korvin, A. (2008). Measuring the leanness of manufacturing systems – a case study of ford motors company and general motors. Journal of Engineering and Technology Management, 25(4), 287-304. http://dx.doi.org/10.1016/j.jengtecman.2008.10.003.
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Malhotra, M. K., & Grover, V. (1998). An assessment of survey research in POM: from constructs to theory. Journal of Operations Management, 16(4), 407-425. http://dx.doi.org/10.1016/S0272-6963(98)00021-7.
Malhotra, N. (2004). Marketing research: an applied orientation (4. ed.). New Jersey: Pearson/Prentice Hall.
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Mathaisel, D. (2005). A lean architecture for transforming the aerospace maintenance, repair and overhaul (MRO) enterprise. International Journal of Productivity and Performance Management, 54(8), 623-644. http://dx.doi.org/10.1108/17410400510627499.
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Motwani, J. (2003). A business process change framework for examining Lean manufacturing: a case study. Industrial Management & Data Systems, 103(5), 339-346. http://dx.doi.org/10.1108/02635570310477398.
Norrman, A., & Jansson, U. (2004). Ericsson’s proactive supply chain risk management approach after a serious sub-supplier accident. International Journal of Physical Distribution & Logistics Management, 34(5), 434-456. http://dx.doi.org/10.1108/09600030410545463.
Nunnally, J. C. (1978). Psychometric theory (2. ed.). New York: McGraw-Hill.
Panizzolo, R. (1998). Appying lessons learned from 27 lean manufactures: the relevance of relationship management. International Journal of Production Economics, 55(3), 223-240. http://dx.doi.org/10.1016/S0925-5273(98)00066-8.
Panizzolo, R., Garengo, P., Sharma, M. K., & Gore, A. (2012). Lean manufacturing in developing countries: evidence from Indian SMEs. Production Planning and Control, 23(10-11), 769-788. http://dx.doi.org/10.1080/09537287.2011.642155.
Papadopoulou, T., & Özbayrak, M. (2005). Leanness experiences from the journey to date. Journal of Manufacturing Technology Management, 16(7), 784-807. http://dx.doi.org/10.1108/17410380510626196.
Pettersen, J. (2009). Defining lean production: some conceptual and practical issues. The TQM Journal, 21(2), 127-142. http://dx.doi.org/10.1108/17542730910938137.
Piercy, N., & Rich, N. (2009). Lean transformation in the pure service environment the case of the call service center. International Journal of Operations & Production Management, 29(1), 54-76. http://dx.doi.org/10.1108/01443570910925361.
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Ritchie, B., & Brindley, C. (2000). Disintermediation, disintegration and risk in the SME global supply chain. Management Decision, 38(8), 575-583. http://dx.doi.org/10.1108/00251740010378309.
Ritchie, B., & Brindley, C. (2007). Supply chain risk management and performance: a guiding framework for future development. International Journal of Operations & Production Management, 27(3), 303-322. http://dx.doi.org/10.1108/01443570710725563.
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Sriparavastu, L., & Gupta, T. (1997). An empirical study of JIT and TQM principles implementation in manufacturing firms in the USA. International Journal of Operations & Production Management, 17(12), 1215-1232. http://dx.doi.org/10.1108/01443579710182954.
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Baker, P. (2002). Why is lean so far off? Works Management, 55(10), 6-15.
Bannerman, P. L. (2008). Risk and risk management in software projects: a reassessment. Journal of Systems and Software, 81(12), 2118-2133. http://dx.doi.org/10.1016/j.jss.2008.03.059.
Bateman, N., & David, A. (2002). Process improvement programmes: a model for assessing sustainability. International Journal of Operations & Production Management, 22(5), 515-526. http://dx.doi.org/10.1108/01443570210425156.
Bayo-Moriones, A., Bello-Pintado, A., & Merino-Díaz-De-Cerio, J. (2008). The role of organizational context and infrastructure practices in JIT implementation. International Journal of Operations & Production Management, 28(11), 1042-1066. http://dx.doi.org/10.1108/01443570810910188.
Bayou, M. E., & Korvin, A. (2008). Measuring the leanness of manufacturing systems – a case study of ford motors company and general motors. Journal of Engineering and Technology Management, 25(4), 287-304. http://dx.doi.org/10.1016/j.jengtecman.2008.10.003.
Bhasin, S. (2012). Prominent obstacles to lean. International Journal of Productivity and Performance Management, 61(4), 403-425. http://dx.doi.org/10.1108/17410401211212661.
Black, J. (2007). Design rules for implementing the Toyota production system. International Journal of Production Research, 45(16), 3639-3664. http://dx.doi.org/10.1080/00207540701223469.
Blanchard, D. (2007). Lean, green and low cost. Industry Week- Cleveland Ohio, 256(10), 37.
Cronbach, L. (1951). Coefficient alpha and the internal structure of tests. Psychiatrika, 16(3), 297-334.
Cua, K. O., McKone, K., & Schroeder, R. G. (2001). Relationships between implementation of TQM, JIT, and TPM and manufacturing performance. Journal of Operations Management, 19(6), 675-694. http://dx.doi.org/10.1016/S0272-6963(01)00066-3.
Emiliani, M., & Stec, D. (2005). Leaders lost in transformation. Leadership and Organization Development Journal, 26(5), 370-387. http://dx.doi.org/10.1108/01437730510607862.
Farris, J., Van Aken, E., Doolen, T., & Worley, J. (2009). Critical success factors for a human resource outcomes in Kaizen events: An empirical study. International Journal of Production Economics, 117(1), 42-65. http://dx.doi.org/10.1016/j.ijpe.2008.08.051.
Field, A. (2005). Discovering statistics using SPSS (2. ed.). London: Sage Publications.
Freitas, W. R. S., Jabbour, C. J. C., Teixeira, A. A., & Jabbour, A. B. L. S. (2014). Gestão de recursos humanos e manufatura enxuta: evidências empíricas do setor automotivo brasileiro. Production, 24(2), 451-461. http://dx.doi.org/10.1590/S0103-65132013005000039.
Golhar, D., Stamm, C., & Smith, W. (1990). JIT implementation in small manufacturing firms. Production and Inventory Management Journal, 31(2), 44-48.
Hair, J. F., Black, B., Babin, B., Anderson, R., & Tatham, R. (2006). Multivariate data analysis (6. ed ). New Jersey: Prentice Hall.
Hallikas, J., Karvonen, I., Pulkkinen, U., Virolainen, V., & Tuominen, M. (2004). Risk management processes in supplier networks. International Journal of Production Economics, 90(1), 47-58. http://dx.doi.org/10.1016/j.ijpe.2004.02.007.
Hines, P., Holweg, M., & Rich, N. (2004). Learning to evolve: A review of contemporary lean thinking. International Journal of Operations & Production Management, 24(10), 994-1011. http://dx.doi.org/10.1108/01443570410558049.
Krafcit, J. F. (1988). Triumph of the lean production system. Sloan Management Review, 30(1), 41-51.
Lander, E., & Liker, J. (2007). The Toyota production system and art: making highly customized and creative products at Toyota way. International Journal of Production Research, 45(16), 3681-3698. http://dx.doi.org/10.1080/00207540701223519.
Lean Enterprise Institute. (2007). New survey: middle managers are biggest obstacle to lean enterprise. Recuperado em 19 de outubro de 2007, de http://www.lean.org
Lian, Y., & Van Landeghem, H. (2007). Analyzing the effects of Lean manufacturing using a value stream mapping-based simulation generator. International Journal of Production Research, 45(13), 3037-3058. http://dx.doi.org/10.1080/00207540600791590.
Lima, M. L., & Zawislak, P. A. (2003). A produção enxuta como fator diferencial na capacidade de fornecimento de PMEs. Production, 13(2), 57-69. http://dx.doi.org/10.1590/S0103-65132003000200006.
Malhotra, M. K., & Grover, V. (1998). An assessment of survey research in POM: from constructs to theory. Journal of Operations Management, 16(4), 407-425. http://dx.doi.org/10.1016/S0272-6963(98)00021-7.
Malhotra, N. (2004). Marketing research: an applied orientation (4. ed.). New Jersey: Pearson/Prentice Hall.
Marodin, G. A., & Saurin, T. A. (2013). Implementing lean production systems: research areas and opportunities for future studies. International Journal of Production Research, 51(22), 6663-6680. http://dx.doi.org/10.1080/00207543.2013.826831.
Marodin, G. A., Saurin, T. A., & Fettermann, D. C. (2014). Uma sistemática para a avaliação de riscos na implantação de produção enxuta. Revista Produção Online, 14(1), 364-401. http://dx.doi.org/10.14488/1676-1901.v14.i1.1667.
Mathaisel, D. (2005). A lean architecture for transforming the aerospace maintenance, repair and overhaul (MRO) enterprise. International Journal of Productivity and Performance Management, 54(8), 623-644. http://dx.doi.org/10.1108/17410400510627499.
Meyers, L., Gamst, G., & Guarino, A. (2006). Applied multivariate research. Thousand Oaks: Sage Publications. Moreira, M., & Alvez, R. (2008). A study on just-in-time implementation in Portugal: some empirical evidence. Brazilian Journal of Operations & Production Management, 5(1), 5-22.
Motwani, J. (2003). A business process change framework for examining Lean manufacturing: a case study. Industrial Management & Data Systems, 103(5), 339-346. http://dx.doi.org/10.1108/02635570310477398.
Norrman, A., & Jansson, U. (2004). Ericsson’s proactive supply chain risk management approach after a serious sub-supplier accident. International Journal of Physical Distribution & Logistics Management, 34(5), 434-456. http://dx.doi.org/10.1108/09600030410545463.
Nunnally, J. C. (1978). Psychometric theory (2. ed.). New York: McGraw-Hill.
Panizzolo, R. (1998). Appying lessons learned from 27 lean manufactures: the relevance of relationship management. International Journal of Production Economics, 55(3), 223-240. http://dx.doi.org/10.1016/S0925-5273(98)00066-8.
Panizzolo, R., Garengo, P., Sharma, M. K., & Gore, A. (2012). Lean manufacturing in developing countries: evidence from Indian SMEs. Production Planning and Control, 23(10-11), 769-788. http://dx.doi.org/10.1080/09537287.2011.642155.
Papadopoulou, T., & Özbayrak, M. (2005). Leanness experiences from the journey to date. Journal of Manufacturing Technology Management, 16(7), 784-807. http://dx.doi.org/10.1108/17410380510626196.
Pettersen, J. (2009). Defining lean production: some conceptual and practical issues. The TQM Journal, 21(2), 127-142. http://dx.doi.org/10.1108/17542730910938137.
Piercy, N., & Rich, N. (2009). Lean transformation in the pure service environment the case of the call service center. International Journal of Operations & Production Management, 29(1), 54-76. http://dx.doi.org/10.1108/01443570910925361.
Project Management Institute. (2004). A guide to the project management body of knowledge (3. ed.). Newtown Square: PMI.
Raz, T., Shenhar, A., & Dvir, D. (2002). Risk management, Project success and technological uncertainity. R & D Management, 32(2), 101-109. http://dx.doi.org/10.1111/1467-9310.00243.
Ritchie, B., & Brindley, C. (2000). Disintermediation, disintegration and risk in the SME global supply chain. Management Decision, 38(8), 575-583. http://dx.doi.org/10.1108/00251740010378309.
Ritchie, B., & Brindley, C. (2007). Supply chain risk management and performance: a guiding framework for future development. International Journal of Operations & Production Management, 27(3), 303-322. http://dx.doi.org/10.1108/01443570710725563.
Saurin, T. A., Ribeiro, J. L. D., & Marodin, G. A. (2010). Identificação de oportunidades de pesquisa a partir de um levantamento da implantação da produção enxuta em empresas do Brasil e do exterior. Gestão & Produção, 17(4), 829-841. http://dx.doi.org/10.1590/S0104-530X2010000400015.
Scherrer-Rathje, M., Boyle, T. A., & Deflorin, P. (2009). Lean, take two! Reflections from the second attempt at lean implementation. Business Horizons, 52(1), 79-88. http://dx.doi.org/10.1016/j.bushor.2008.08.004.
Serviço Brasileiro de Apoio às Micro e Pequenas Empresas. (2011). Critérios e conceitos para classificação de empresas. Goiânia: SEBRAE. Recuperado em 3 de novembro de 2011, de http://www.sebrae.com.br/uf/goias/indicadores-das-mpe/classificacao-empresarial
Shah, R., & Ward, P. (2003). Lean manufacturing: context, practice bundles, and performance. Journal of Operations Management, 21(2), 129-149. http://dx.doi.org/10.1016/S0272-6963(02)00108-0.
Sim, K., & Rogers, J. (2008). Implementing lean production systems: barriers to change. Management Research News, 32(1), 37-49. http://dx.doi.org/10.1108/01409170910922014.
Sriparavastu, L., & Gupta, T. (1997). An empirical study of JIT and TQM principles implementation in manufacturing firms in the USA. International Journal of Operations & Production Management, 17(12), 1215-1232. http://dx.doi.org/10.1108/01443579710182954.
Sumner, M. (2000). Risk factors in enterprise-wide/ERP projects. Journal of Information Technology, 15(4), 317-327. http://dx.doi.org/10.1080/02683960010009079.
Tabachnick, B. G., & Fidell, L. S. (2001).Using multivariate statistics (4 ed.). Boston: Allyn & Bacon.
Taj, S., & Morosan, C. (2011). The impact of lean operations on the Chinese manufacturing performance. Journal of Manufacturing Technology Management, 22(2), 223-240. http://dx.doi.org/10.1108/17410381111102234.
Tang, C. (2006). Perspectives in supply chain risk management. International Journal of Production Economics, 103(2), 451-488. http://dx.doi.org/10.1016/j.ijpe.2005.12.006.
Turesky, E. F., & Connell, P. (2010). Off the rails: understanding the derailment of a Lean manufacturing initiative. Organizational Management Journal, 7(2), 110-132. http://dx.doi.org/10.1057/omj.2010.14.
Umbach, P. (2004). Web surveys: best practices. In J. F. Ryan & G. Crisp (Eds.), New directions for institutional research (pp. 23-38). New York: Wiley On-line Library.
Wallace, L., Keil, M., & Rai, A. (2004). Understanding software project risk: a cluster analysis. Information & Management, 42(1), 115-125. http://dx.doi.org/10.1016/j.im.2003.12.007.
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