Análise da mudança de um sistema de produção empurrado para puxado: uma pesquisa-ação em uma cadeia produtiva terceirizada de cosméticos
Autor(a) principal: | |
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Data de Publicação: | 2020 |
Tipo de documento: | Dissertação |
Idioma: | por |
Título da fonte: | Repositório Institucional do FGV (FGV Repositório Digital) |
Texto Completo: | https://hdl.handle.net/10438/28834 |
Resumo: | The objective of this thesis is to study the application of lean methodology in an outsourced cosmetics production chain, through the implementation of an intervention in the production system of the dyad formed between the cosmetics company and its outsourced manufacturer, changing the production process from a push to a pull system. The original context of this production chain under the push system presented a scenario with long lead times and unbalanced finished product and raw materials stocks, leading the author to propose an action research in which an intervention was developed in the production system of two SKUs to solve those issues. It was selected two SKUs from two different factories of the same outsourced manufacturer to evaluate the effects of this intervention in two different production environments. In this intervention, lean methodology tools were used as the value stream mapping that detailed the original state of the pushed system, allowing to collect and analyze the data from this original context. Then, the future state map was developed which considered the principle of lean methodology that guides the production system pulled by the real demand. The planning and execution of this intervention were detailed in this paper to present the preparation and training stages of the involved team, development of current and future maps, pull system calculation, implementation schedules and results evaluation. Following the implementation of this change, the sales forecast, lead time and inventory indicators were analyzed under the new pull production system condition. Sales forecast accuracy was improved by over 70%, lead time significantly reduced by about 65%, and an important reduction in inventory levels was identified with the two SKUs analyzed, with 18% for the SKU produced at the cream factory and about 37% for the fragrance SKU. In addition to these results, interviews with key participants of this intervention revealed the main challenges, benefits and opportunities in this process of promoting such a complex change in an outsourced production chain and in a highly volatile demand environment. |
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Fonseca, Henrique VarelaEscolas::EAESPMiguel, Priscila Laczynski de SouzaRodrigues, FabianoVasconcellos, Luís Henrique Rigato2020-02-27T12:51:59Z2020-02-27T12:51:59Z2020-02-21https://hdl.handle.net/10438/28834The objective of this thesis is to study the application of lean methodology in an outsourced cosmetics production chain, through the implementation of an intervention in the production system of the dyad formed between the cosmetics company and its outsourced manufacturer, changing the production process from a push to a pull system. The original context of this production chain under the push system presented a scenario with long lead times and unbalanced finished product and raw materials stocks, leading the author to propose an action research in which an intervention was developed in the production system of two SKUs to solve those issues. It was selected two SKUs from two different factories of the same outsourced manufacturer to evaluate the effects of this intervention in two different production environments. In this intervention, lean methodology tools were used as the value stream mapping that detailed the original state of the pushed system, allowing to collect and analyze the data from this original context. Then, the future state map was developed which considered the principle of lean methodology that guides the production system pulled by the real demand. The planning and execution of this intervention were detailed in this paper to present the preparation and training stages of the involved team, development of current and future maps, pull system calculation, implementation schedules and results evaluation. Following the implementation of this change, the sales forecast, lead time and inventory indicators were analyzed under the new pull production system condition. Sales forecast accuracy was improved by over 70%, lead time significantly reduced by about 65%, and an important reduction in inventory levels was identified with the two SKUs analyzed, with 18% for the SKU produced at the cream factory and about 37% for the fragrance SKU. In addition to these results, interviews with key participants of this intervention revealed the main challenges, benefits and opportunities in this process of promoting such a complex change in an outsourced production chain and in a highly volatile demand environment.Este trabalho tem como objetivo o estudo da aplicação da metodologia lean em uma cadeia produtiva terceirizada de cosméticos, através da implementação de uma intervenção no sistema de produção da díade formada entre a empresa de cosméticos e seu fabricante terceirizado, alterando a lógica de produção de sistema empurrado para sistema puxado. O contexto original desta cadeia produtiva sob a lógica de produção empurrada apresentava um cenário de longos lead times e estoques de produto acabado e insumos desbalanceados, levando o autor a propor uma pesquisa-ação na qual foi desenvolvida uma intervenção no sistema de produção de dois SKUs selecionados para o cumprimento do objetivo proposto. Foram investigadas duas fábricas distintas do mesmo fabricante terceirizado para avaliar os efeitos desta intervenção em dois ambientes de produção diferentes. Nesta intervenção, foram utilizadas ferramentas da metodologia lean, como o mapeamento de fluxo de valor, que detalharam a situação original do sistema empurrado, permitindo coletar e analisar os dados deste contexto original. Em seguida, foi desenvolvido o mapa do estado futuro, o qual considerou o princípio da metodologia lean que norteia o sistema de produção puxado pela demanda real. O planejamento e a execução desta intervenção foram detalhados neste trabalho de forma a apresentar as etapas de preparação e treinamento da equipe envolvida, desenvolvimento dos mapas atual e futuro, dimensionamento do sistema puxado, cronogramas de implementação e avaliação de resultados. Após a implementação dessa mudança, foram analisados os indicadores de previsão de vendas, lead time e estoques sob a nova condição do sistema de produção puxado. Observou- -se uma melhora na acuracidade da previsão de vendas em mais de 70%, uma significativa redução dos lead times entre o momento do pedido e a respectiva entrega em cerca de 65% e uma redução importante dos níveis de inventários dos dois SKUs, sendo de 18% para o SKU da fábrica de cremes e de cerca de 37% para o SKU de fragrância. Além desses resultados, as entrevistas realizadas com os principais participantes desta intervenção revelaram os principais desafios, benefícios e oportunidades neste processo de promover uma mudança tão complexa em uma cadeia de produção terceirizada e diante de um ambiente de alta volatilidade de demanda.porLead timeInventoryLeanValue stream mappingPush SystemPull systemInventárioMapeamento de fluxo de valorSistema empurradoSistema puxadoAdministração de empresasAdministração da produçãoControle de produçãoProdução enxutaInventáriosLogística empresarialAnálise da mudança de um sistema de produção empurrado para puxado: uma pesquisa-ação em uma cadeia produtiva terceirizada de cosméticosinfo:eu-repo/semantics/publishedVersioninfo:eu-repo/semantics/masterThesisinfo:eu-repo/semantics/openAccessreponame:Repositório Institucional do FGV (FGV Repositório Digital)instname:Fundação Getulio Vargas (FGV)instacron:FGVORIGINALTrabalho Aplicado_Henrique Fonseca_MPGC_FGV_revisao final.pdfTrabalho 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|
dc.title.por.fl_str_mv |
Análise da mudança de um sistema de produção empurrado para puxado: uma pesquisa-ação em uma cadeia produtiva terceirizada de cosméticos |
title |
Análise da mudança de um sistema de produção empurrado para puxado: uma pesquisa-ação em uma cadeia produtiva terceirizada de cosméticos |
spellingShingle |
Análise da mudança de um sistema de produção empurrado para puxado: uma pesquisa-ação em uma cadeia produtiva terceirizada de cosméticos Fonseca, Henrique Varela Lead time Inventory Lean Value stream mapping Push System Pull system Inventário Mapeamento de fluxo de valor Sistema empurrado Sistema puxado Administração de empresas Administração da produção Controle de produção Produção enxuta Inventários Logística empresarial |
title_short |
Análise da mudança de um sistema de produção empurrado para puxado: uma pesquisa-ação em uma cadeia produtiva terceirizada de cosméticos |
title_full |
Análise da mudança de um sistema de produção empurrado para puxado: uma pesquisa-ação em uma cadeia produtiva terceirizada de cosméticos |
title_fullStr |
Análise da mudança de um sistema de produção empurrado para puxado: uma pesquisa-ação em uma cadeia produtiva terceirizada de cosméticos |
title_full_unstemmed |
Análise da mudança de um sistema de produção empurrado para puxado: uma pesquisa-ação em uma cadeia produtiva terceirizada de cosméticos |
title_sort |
Análise da mudança de um sistema de produção empurrado para puxado: uma pesquisa-ação em uma cadeia produtiva terceirizada de cosméticos |
author |
Fonseca, Henrique Varela |
author_facet |
Fonseca, Henrique Varela |
author_role |
author |
dc.contributor.unidadefgv.por.fl_str_mv |
Escolas::EAESP |
dc.contributor.member.none.fl_str_mv |
Miguel, Priscila Laczynski de Souza Rodrigues, Fabiano |
dc.contributor.author.fl_str_mv |
Fonseca, Henrique Varela |
dc.contributor.advisor1.fl_str_mv |
Vasconcellos, Luís Henrique Rigato |
contributor_str_mv |
Vasconcellos, Luís Henrique Rigato |
dc.subject.eng.fl_str_mv |
Lead time Inventory Lean Value stream mapping Push System Pull system |
topic |
Lead time Inventory Lean Value stream mapping Push System Pull system Inventário Mapeamento de fluxo de valor Sistema empurrado Sistema puxado Administração de empresas Administração da produção Controle de produção Produção enxuta Inventários Logística empresarial |
dc.subject.por.fl_str_mv |
Inventário Mapeamento de fluxo de valor Sistema empurrado Sistema puxado |
dc.subject.area.por.fl_str_mv |
Administração de empresas |
dc.subject.bibliodata.por.fl_str_mv |
Administração da produção Controle de produção Produção enxuta Inventários Logística empresarial |
description |
The objective of this thesis is to study the application of lean methodology in an outsourced cosmetics production chain, through the implementation of an intervention in the production system of the dyad formed between the cosmetics company and its outsourced manufacturer, changing the production process from a push to a pull system. The original context of this production chain under the push system presented a scenario with long lead times and unbalanced finished product and raw materials stocks, leading the author to propose an action research in which an intervention was developed in the production system of two SKUs to solve those issues. It was selected two SKUs from two different factories of the same outsourced manufacturer to evaluate the effects of this intervention in two different production environments. In this intervention, lean methodology tools were used as the value stream mapping that detailed the original state of the pushed system, allowing to collect and analyze the data from this original context. Then, the future state map was developed which considered the principle of lean methodology that guides the production system pulled by the real demand. The planning and execution of this intervention were detailed in this paper to present the preparation and training stages of the involved team, development of current and future maps, pull system calculation, implementation schedules and results evaluation. Following the implementation of this change, the sales forecast, lead time and inventory indicators were analyzed under the new pull production system condition. Sales forecast accuracy was improved by over 70%, lead time significantly reduced by about 65%, and an important reduction in inventory levels was identified with the two SKUs analyzed, with 18% for the SKU produced at the cream factory and about 37% for the fragrance SKU. In addition to these results, interviews with key participants of this intervention revealed the main challenges, benefits and opportunities in this process of promoting such a complex change in an outsourced production chain and in a highly volatile demand environment. |
publishDate |
2020 |
dc.date.accessioned.fl_str_mv |
2020-02-27T12:51:59Z |
dc.date.available.fl_str_mv |
2020-02-27T12:51:59Z |
dc.date.issued.fl_str_mv |
2020-02-21 |
dc.type.status.fl_str_mv |
info:eu-repo/semantics/publishedVersion |
dc.type.driver.fl_str_mv |
info:eu-repo/semantics/masterThesis |
format |
masterThesis |
status_str |
publishedVersion |
dc.identifier.uri.fl_str_mv |
https://hdl.handle.net/10438/28834 |
url |
https://hdl.handle.net/10438/28834 |
dc.language.iso.fl_str_mv |
por |
language |
por |
dc.rights.driver.fl_str_mv |
info:eu-repo/semantics/openAccess |
eu_rights_str_mv |
openAccess |
dc.source.none.fl_str_mv |
reponame:Repositório Institucional do FGV (FGV Repositório Digital) instname:Fundação Getulio Vargas (FGV) instacron:FGV |
instname_str |
Fundação Getulio Vargas (FGV) |
instacron_str |
FGV |
institution |
FGV |
reponame_str |
Repositório Institucional do FGV (FGV Repositório Digital) |
collection |
Repositório Institucional do FGV (FGV Repositório Digital) |
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