Efeito da redução do tamanho de lote e de programas de Melhoria Contínua no Estoque em Processo (WIP) e na Utilização: estudo utilizando uma abordagem híbrida System Dynamics - Factory Physics
Effect of lot size reduction and Continuous Improvement on Work In Process and Utilization: study using a combined System Dynamics and Factory Physics approach
Godinho Filho, Moacir; Uzsoy, Reha
http://dx.doi.org/10.1590/S0103-65132009000100014
Prod, vol.19, n1, p.214-229, 2009
Resumo
O presente trabalho apresenta um modelo quantitativo que utiliza de forma híbrida as abordagens System Dynamics - SD (FORRESTER, 1962) e Factory Physics (HOPP; SPEARMAN, 2001) objetivando estudar o efeito conjunto de seis programas de Melhoria Contínua - CI (variabilidade na taxa de chegada, variabilidade do processo, qualidade, tempo até a falha, tempo de reparo e tempo de set up) e de redução de tamanhos de lote de produção nos níveis médios de Estoque em Processo (WIP) e Utilização em um ambiente produtivo com uma única máquina que processa múltiplos produtos. Os resultados dos experimentos realizados utilizando-se o modelo desenvolvido fornecem insights e subsídios que dão suporte a uma série de modernas ferramentas e filosofias de gestão da manufatura, tais como programas de redução da variabilidade do processo como, por exemplo, Seis Sigma; programas de redução de set up, como por exemplo os programas SMED (Single Minute Exchange of Die), Sistema Toyota de Produção/Manufatura Enxuta e Quick Response Manufacturing (QRM). Além disso, o modelo também serve para auxiliar na escolha de diferentes possibilidades de programas de Melhoria Contínua no chão de fábrica.
Palavras-chave
Tamanho de lote de produção, Melhoria Contínua, Estoque em Processo, Utilização, System Dynamics, Factory Physics
Abstract
This paper builds a quantitative model, which is a result of a combination of System Dynamics (FORRESTER, 1962) and Factory Physics (HOPP; SPEARMAN, 2001) approaches aiming to examine how six Continuous Improvement (CI) programs (arrival variability, process variability, quality (defect rate), time to failure, repair time, and set up time), together with lot size reduction, affect Work In Process (WIP) and Utilization in a multi-product, single-machine environment. Results of the paper provides support for: i) the importance of implementing set up reduction programs; ii) Lean Manufacturing (LM) philosophy regarding the implementation of small CI programs in a lot of variables and areas of the shop floor; iii) Quick Response Manufacturing (QRM) philosophy regarding the importance of managers to know the convex relationship between lot size and WIP in order to decide the amount of lot size reduction to be performed on shop floor; iv) the choice between alternative CI programs.
Keywords
Lot Size, Continuous Improvement, Work In Process, Utilization, System Dynamics, Factory Physics.
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