Principles and practices of lean production applied in a metal structures production system

Abstract

This paper presents a work undertaken in a metal structures production system in a company producing several assorted products for the civil construction. The work aim was to improve the production process, solving several productive problems encountered in the production system, such as: deliveries delays, long lead times, too many material handling, high stocks, errors and defects in metal structures assembly and production, and unnecessary motions. The identified problems were analyzed and improvement actions were scheduled and subsequently implemented. These improvement actions were based on Lean production organizational model and some Lean tools. The 5S methodology was implemented in the workplace as well as mistake proofing mechanism, standardized procedures, production activity control system and layout reconfiguration. These actions led to a reduction of the lead time, work in progress, transports, delivery delays, defects and errors in assembly and production.