Application of chronoanalysis and value stream map techniques to improve the production capacity of an automotive plant in the Manaus Free Trade Zone

Abstract

Industries in general are challenged to produce more and better, even though the business environment in which they operate is uncertain and turbulent. This requires cost reduction and process improvement, which can be achieved with the tools of Lean Manufacturing. The general objective of the study is to clarify the application of chronoanalysis and Value Stream Mapping for improving the production capacity of an automotive factory in the Free Trade Zone of Manaus. It is a bibliographic, exploratory study of a quantitative nature, supported by a case study. The investigative practice included the execution of time studies and the creation of a Value Stream Map in the production and logistics sectors. After carrying out these procedures, it was possible to obtain na increase in capacity and a previous target of 52 products per day to a new target of 58 products per day, with an effective increase of 6 products per day, representing an 11.54% of gain in installed capacity. In addition, financial gains of R$ 988,000.00 per year were achieved through the optimization of 10 direct labor staff in logistics and R$ 1,679,600.00 per year through the optimization of 17 direct labor in production. The study concludes that both chronoanalysis and the Value Stream Map are effective methods, especially regarding the pursuit of excellence in processes combined with the reduction of waste in production processes.