Proposal of lead time reduction in the thermoelectric products line of a small company in the State of Sao Paulo

Abstract

Quick Response Manufacturing (QRM) is a way manufacturing companies may increase their flexibility. Manufacturing flexibility is a key to differentiation and enhancement of competitiveness. There is few empirical research on the topic of how small and medium-sized enterprises (SME) may benefit from QRM, what may impact the appropriation of this approach by these important actors of our economy. This article aims to present the results of a project which applied QRM to reduce the lead time of a small company located in the state of Sao Paulo. It was proposed to a) balance the throughputs of slow operations, reducing 50% of production batches; b) implement cellular manufacturing and improvements in the management of Work In Process, using the POLCA system and visual management; c) implement an integrated sales and operations planning (S&OP) and rules for prioritization of orders. It was identified that the proposal would generate a lead time reduction from 39 to 21.3 days and a decrease of at least 51% in the raw materials stock costs. During the research, the following conclusions could be drawn: a) problems in management, investment capacity and relationship with suppliers are frequent in family-owned SMEs; b) QRM approach can be adapted to work within this environment; c) the knowledge developed in academia can be an important tool to help family-owned SMEs to supplant these obstacles.

Keywords

• pequena empresa familiar. Redução de lead time. Quick Response Manufacturing