Lean Seis Sigma Graziele Moro MANI Fabiana Serralha Miranda de PÁDUA Resumo
Lean Seis Sigma Graziele Moro MANI Fabiana Serralha Miranda de PÁDUA Resumo
Lean Seis Sigma Graziele Moro MANI Fabiana Serralha Miranda de PÁDUA Resumo
1 - 2008
RESUMO
'HYLGRjJOREDOL]DomRDFRQFRUUrQFLDWRUQRXVHPDLVDFHQWXDGD'HVWDIRUPDDVHPSUHVDVQHFHVVLWDP
buscar ou desenvolver novas metodologias e técnicas de gestão para se manterem competitivas. O
/HDQ6HLV6LJPDUHSUHVHQWDXPDDERUGDJHPLQWHJUDGDGHGXDVPHWRGRORJLDVTXHVHGHVHQYROYHUDP
SRUpPSRGHPVHU XWLOL]DGDV GHIRUPDLQGLYLGXDO6HLV6LJPDHLean (QWUHWDQWRDV YDQWDJHQVGD
LPSOHPHQWDomRLQWHJUDGDGDVGXDVDERUGDJHQVWrPVHPRVWUDGREDVWDQWHVLJQL¿FDWLYDV(VWHDUWLJR
teve como objetivo demonstrar a importância da junção dos métodos Lean 0DQXIDFWXULQJ e Seis
Sigma para reduzir desperdícios e custos de forma a aumentar a qualidade e velocidade de entrega
GRVSURGXWRVDRVFOLHQWHV3DUDRDOFDQFHGRREMHWLYRIRLUHDOL]DGDXPDSHVTXLVDELEOLRJUi¿FDVHJXLGD
por uma pesquisa de campo em uma empresa de grande porte de bens de capital em Araraquara (SP).
&RQFOXLVHTXHSRUPHLRGDDSOLFDomRGR'0$,&HGDVIHUUDPHQWDVXWLOL]DGDVQDPDQXIDWXUDHQ[XWD
pSRVVtYHOGHWHUPLQDUHTXDQWL¿FDURVSULQFLSDLVGHIHLWRVHHPTXDLVSURFHVVRVKiPDLVGHVSHUGtFLRV
podendo analisar as causas dos defeitos Lean SDUDRHVWDEHOHFLPHQWRGHDo}HVGHPHOKRULDPHOKRUDQGR
DH¿FLrQFLDGDHPSUHVD
PALAVRAS-CHAVE/HDQ0DQXIDFWXULQJ6HLV6LJPD/HDQ6HLV6LJPD'0$,&
INTRODUÇÃO
Com o mundo cada vez mais globalizado as empresas estão inseridas num cenário de competição. Em
UHVSRVWDDVRUJDQL]Do}HVEXVFDPPHOKRUDUVHXVSURFHVVRVHSURGXWRVSDUDREWHUPDLRUHVYDQWDJHQV
FRPSHWLWLYDVGHPRGRDDWHQGHUDVH[SHFWDWLYDVGHVHXVFOLHQWHVHDFLRQLVWDV$EXVFDSRUSURGX]LUR
Pi[LPRGHYDORUXWLOL]DQGRRPtQLPRGHUHFXUVRVWrPRULHQWDGRRVHVIRUoRVGRPXQGRFRUSRUDWLYR
moderno para novas técnicas de gerenciamento como o Lean Seis Sigma. A fundamentação do consiste
QRSHQVDPHQWRHQ[XWRHR6HLV6LJPDWHPFRPRREMHWLYRDPHOKRULDFRQWtQXDYLVDQGRDUHGXomRGH
YDULDELOLGDGHGHSURFHVVRV6HPSUHFRPRIRFRQRFOLHQWHR/HDQ6HLV6LJPDEDVHLDVHHPIDWRVHQD
XWLOL]DomRGHIHUUDPHQWDVGDTXDOLGDGHSDUDLGHQWL¿FDUHPLQLPL]DUDVFDXVDVHHIHLWRVGRVSUREOHPDV
Seis Sigma
6HLV6LJPDpDLQÀH[tYHOHULJRURVDEXVFDGDYDULDomRHPWRGRVRVSURFHVVRVFUtWLFRVSDUDDOFDQoDU
PHOKRULDV FRQWtQXDV H TXkQWLFDV TXH LPSDFWDP RV tQGLFHV GH XPD RUJDQL]DomR DXPHQWDQGR D
satisfação e lealdade dos clientes. Ë uma iniciativa organizacional projetada para criar processos de
PDQXIDWXUDVHUYLoRRXDGPLQLVWUDWLYRTXHJHUHPQRPi[LPRGHIHLWRVSRUPLOKmRGHRSRUWXQLGDGHV
$IHUUDPHQWDGHPHOKRULDHPSUHJDGDQDLPSODQWDomRGRVSURMHWRV6HLV6LJPDpR'0$,&VLJODTXH
VLJQL¿FD'H¿QLU±0HGLU±$QDOLVDU±,PSOHPHQWDU±&RQWURODU5$6,6S
___________________
'LFHQWHGD)DFXOGDGHGH7HFQRORJLDGH7DTXDULWLQJDJUDBPDQL#KRWPDLOFRP
'RFHQWHGD)DFXOGDGHGH7HFQRORJLDGH7DTXDULWLQJDSISDGXD#XROFRPEU
115
INTERFACE TECNOLÓGICA - v.5 - n.1 - 2008
2 VtPEROR 6LJPD ı p GR DOIDEHWR JUHJR H p XWLOL]DGR SDUD LQGLFDU D YDULDomR VREUH D PpGLD GH
XPSURFHVVR4XDQGRRVLJPDpDSOLFDGRDXPSURFHVVRRVHXYDORULQGLFDVHRPHVPRHVWiVHQGR
FRQWURODGRXPPDLRUQtYHOVLJPDVLJQL¿FDTXHH[LVWHXPPHQRUQ~PHURGHGHIHLWRVDVVRFLDGRVDR
SURFHVVRJHUDQGRXPPHQRUFXVWRGHUHWUDEDOKRHSHUGDV2QtYHOVLJPDUHSUHVHQWDRGHVHPSHQKR
GRSURFHVVRLVWRpDVXDFDSDFLGDGHHPDWHQGHUjVHVSHFL¿FDo}HV2JUDXGHTXDOLGDGH6HLV6LJPD
UHSUHVHQWD XP GHVHPSHQKR GH GH FRQIRUPLGDGH RX SDUWHV SRU PLOKmR GH QmR
FRQIRUPLGDGHV0,7&+(//
26HLV6LJPDpDSOLFDGRDWUDYpVGDPHWRGRORJLD'0$,&TXHpXWLOL]DGDQDUHVROXomRGHSUREOHPDV
2 '0$,& p GLUHFLRQDGRU GRV SURMHWRV GH PHOKRULD VHQGR DSUHVHQWDGR HP FLQFR HWDSDV TXH VmR
DSUHVHQWDGDVQD,OXVWUDomR&2521$'2$1721<
Etapas Atribuições
,GHQWL¿FDUTXDOSURFHVVRVHUiHVWXGDGRTXDLVVmRVHXVOLPLWHVGHDEUDQJrQFLDVHXFOLHQWHHR
'H¿QLomR'H¿QH)
que é defeito para o produto deste processo.
(ODERUDomRGRPDSDGHSURFHVVRLGHQWL¿FDQGRWRGRVRVVXESURFHVVRVHHWDSDVGRSURFHVVR
Medição (Measure)
FKDYHDQWHULRUPHQWHGH¿QLGDV
8WLOL]DQGRVH GH IHUUDPHQWDV FRPR R SURMHWR GH H[SHULPHQWRV H WpFQLFDV GH RWLPL]DomR
Melhoria (,PSURYH) VmRHVWDEHOHFLGRVOLPLWHVyWLPRVGHWROHUkQFLDSDUDDVYDULiYHLVGHHQWUDGDPLQLPL]DQGRD
variabilidade das variáveis de saída a que se referem.
Realiza-se uma forma de controle estatístico sobre as variáveis de entrada de forma que
SHUPDQHoDPGHQWURGRVOLPLWHVRSHUDFLRQDLVHVSHFL¿FDGRVQDHWDSDDQWHULRU$OpPGLVVRp
Controle (Control)
HIHWXDGR XP SODQR GH FRQWUROH HVWDEHOHFHQGR DV YDULiYHLV GH HQWUDGD D VHUHP FRQWURODGDV
IRUPDGHFRQWUROHHPHGLomRIUHTrQFLDGHFROHWDGHGDGRVHRVOLPLWHVyWLPRVGHWUDEDOKR
,OXVWUDomR(WDSDVHDWULEXLo}HVGRPpWRGR'0$,&
)RQWH$GDSWDGRGH:HUNHPD
Os benefícios do Seis Sigma são os principais atrativos que despertam o interesse das empresas pelo
programa. O método tem como objetivo eliminar ou reduzir atividades que não agreguem valor ao
SURGXWRRXSURFHVVRDOpPGHEXVFDUDPD[LPL]DomRGDTXDOLGDGHRTXHSURSRUFLRQDXPDUHGXomR
de custos e aumento do lucro da empresa. Com essa otimização e controle de processos torna-se
PDLVIiFLOHOLPLQDURXUHGX]LURVGHIHLWRVHFXLGDUSDUDTXHQmRVXUMDPRSRUWXQLGDGHVGHHUURSRLV
DVIDOKDVWRUQDPRSURGXWRPDLVFDURHPHQRVFRQ¿iYHODOpPGHGHVDSRQWDURVFOLHQWHVHGHL[iORV
LQVDWLVIHLWRV3RGHVHGHVWDFDUR6HLV6LJPDFRPRXPDIHUUDPHQWDHPSUROGDFRPSHWLWLYLGDGHMiTXH
HVWiHPSHQKDGDHPUHGXomRGHIDOKDVSURSRUFLRQDQGRDVVLPXPDPHOKRUTXDOLGDGHGRVSURGXWRVH
SURFHVVRVGDRUJDQL]DomRTXHVHUmRUHÀHWLGRVHPEHQHItFLRVSDUDRVFOLHQWHV
Lean Manufacturing
116
INTERFACE TECNOLÓGICA - v.5 - n.1 - 2008
O conceito LeanYLVDOHYDUDVHPSUHVDVDRTXHVHFKDPDGHRUJDQL]DomRHQ[XWDSRUPHLRGDHOLPLQDomR
GH GHVSHUGtFLR HP WRGD D FDGHLD GH YDORU GD HPSUHVD DOLQKDQGR DWLYLGDGHV GD PHOKRU IRUPD QR
VHQWLGRGHVHREWHUHPSUHVDVPDLVÀH[tYHLVHFDSD]HVGHUHVSRQGHUHIHWLYDPHQWHjVQHFHVVLGDGHVGRV
clientes.
1DHVVrQFLDGR/HDQ0DQXIDFWXULQJHVWiDUHGXomRGRVVHWHWLSRVGHGHVSHUGtFLRVTXHVmRGH¿QLGRV
SRU2KQRHVWHVGHVSHUGtFLRVVmRGHIHLWRVQRVSURGXWRVH[FHVVRGHSURGXomRSURFHVVDPHQWR
PRYLPHQWRHWUDQVSRUWHGHVQHFHVViULRVWHPSRGHHVSHUDHHVWRTXHGHPHUFDGRULDV2DQWtGRWRSDUD
DHOLPLQDomRGHGHVSHUGtFLRVpRSHQVDPHQWRHQ[XWR2LeanDSUHVHQWDFLQFRSULQFtSLRVTXHVmR
HVSHFL¿FDURYDORUDTXLORTXHRFOLHQWHYDORUL]DLGHQWL¿FDURÀX[RGHYDORUFULDUÀX[RVFRQWtQXRV
WHUXPDSURGXomRSX[DGDHEXVFDUDSHUIHLomR3DUDFRORFDUHVVHVSULQFtSLRVHPSUiWLFDRLean conta
FRPRDX[tOLRGHIHUUDPHQWDVFRPRRPDSHDPHQWRGRÀX[RGHYDORU.DL]HQ.DQEDQ3DGURQL]DomR
H6/($1,167,787(%5$6,/
)DWRUHVFRPRTXDOLGDGHWHPSRHFXVWRVmRREMHWLYRVTXHGHYHPVHUDOFDQoDGRVGHIRUPDFRQMXQWD
3DUDTXHHVVHVREMHWLYRVVHMDPDWLQJLGRVDVLQG~VWULDVHSUHVWDGRUDVGHVHUYLoRVWrPUHDOL]DGRJUDQGHV
esforços e vem cada vez mais usufruindo de ferramentas como o Lean para promover e garantir a
PHOKRULD FRQWtQXD GR SURFHVVR GH PDQXIDWXUD H VHUYLoRV GH PRGR D JDUDQWLU XPD VyOLGD SRVLomR
no mercado em que atua. O /HDQ 0DQXIDFWXULQJ p XPD ¿ORVR¿D GH JHUHQFLDPHQWR TXH SURFXUD
RWLPL]DUDRUJDQL]DomRGHIRUPDDDWHQGHUDVQHFHVVLGDGHVGRVFOLHQWHVQRPHQRUSUD]RSRVVtYHOQD
PDLVDOWDTXDOLGDGHHDRPHQRUFXVWRDRPHVPRWHPSRHPTXHDXPHQWDDVHJXUDQoDHDPRWLYDomR
GRVFRODERUDGRUHVSRLVHQYROYHHLQWHJUDQmRVyDPDQXIDWXUDPDVWRGDVDVSDUWHVGDRUJDQL]DomR
'$<&+280
/HDQ6HLV6LJPDpXPDPHWRGRORJLDGHPHOKRULDGHQHJyFLRVTXHPD[LPL]DRYDORUGRDFLRQLVWDDR
DOFDQoDUDWD[DGHPHOKRULDPDLVUiSLGDHPVDWLVIDomRGHFOLHQWHVFXVWRVTXDOLGDGHYHORFLGDGHGH
SURFHVVRVHFDSLWDOLQYHVWLGR*(25*(S
3DUDDLPSODQWDomREHPVXFHGLGDGHXPSURJUDPD/HDQ6HLV6LJPDpIXQGDPHQWDOTXHRSURFHVVR
VHMDFRQGX]LGRH¿FLHQWHPHQWH1DGH¿QLomRGHTXDOTXHULQLFLDWLYDSDUDPHOKRULDHPSUHVDULDOpGH
H[WUHPDLPSRUWkQFLDTXHHODHVWHMDOLJDGDDRVREMHWLYRVHVWUDWpJLFRVGDRUJDQL]DomR&DVRLVVRQmR
117
INTERFACE TECNOLÓGICA - v.5 - n.1 - 2008
RFRUUDTXDOTXHULQLFLDWLYDIRUQHFHUiUHVXOWDGRVGHFXUWRSUD]RTXHLUmRSHUGHUDLPSRUWkQFLDSDUDD
RUJDQL]DomRDRORQJRGRWHPSR)(51$1'(6
&RQIRUPH )HUQDQGHV R SURFHVVR GH LPSOHPHQWDomR GR /HDQ 6HLV 6LJPD GHQWUR GH XPD
RUJDQL]DomRGHYHVHJXLUVHWHHWDSDVTXHVHUmRGHVFULWDVDVHJXLU
'H¿QLUDLQIUDHVWUXWXUDHRSODQRGHLPSOHPHQWDomR
Promover um evento de lançamento que representa um marco para iniciar o engajamento dos
líderes da organização.
&RPRFRQVHTXrQFLDGRODQoDPHQWRGRSURJUDPDRVOtGHUHVFKDYHGDRUJDQL]DomRGHYHPGH¿QLU
RV SULQFLSDLV DJHQWHV GR SURFHVVR FRPR RV 'HSOR\PHQW Managers Master Black Belts e os
primeiros Black Belts.
&RPRUHVXOWDGRGHXPDDQiOLVHGDVHVWUDWpJLDVGDVXQLGDGHVGHQHJyFLRGHYHPVHUVHOHFLRQDGRV
os primeiros projetos Lean Seis Sigma.
Os Master Black Belts e Black Belts devem receber treinamento intensivo. Normalmente são
WUHLQDPHQWRVGHTXDWURDVHLVVHPDQDVFRPLQWHUYDORVRQGHRVSDUWLFLSDQWHVMiGHYHPFRPHoDUD
trabalhar nas atividades de projetos.
1RGHFRUUHUGDVDWLYLGDGHVGHWUHLQDPHQWRRVOtGHUHVFRQWLQXDPSDUWLFLSDQGRGHWUHLQDPHQWRV
fechamento de etapas de projetos e eventos de comunicação.
2SURFHVVRGHYHVHUGH¿QLGRSDUDFRPHoDUDJHUDUEHQHItFLRVHVXSRUWDURLQYHVWLPHQWRUHDOL]DGRj
PHGLGDTXHVHGHVHQYROYH&DVRMiDFRQWHoDPJDQKRVDSDUWLUGRVSULPHLURVSURMHWRVRSURJUDPD
¿FDEDVWDQWHIRUWDOHFLGR
2/HDQ6HLV6LJPDVHJXHXPHVTXHPDGHQRPLQDGR'0$,&'H¿QLU±0HGLU±$QDOLVDU±,PSOHPHQWDU
±&RQWURODUHVXDHTXLSHpFRPSRVWDSHODVVHJXLQWHVSRVLo}HVFRQIRUPH)HUQDQGHV
x &KDPSLRQpRJHVWRUGHWRSRTXHJDUDQWHTXHRSURMHWRHVWiGHDFRUGRFRPDVSULRULGDGHVGD
empresa e é responsável em orientar os esforços para o determinado objetivo. Reporta-se ao
diretor geral.
x SponsorJHVWRUGHOLQKDRXSURFHVVRFDEHDHOHPRQLWRUDUDVDOWHUDo}HVHIHWXDGDVSHODHTXLSHe
TXHPHOLPLQDEDUUHLUDVSDUDDLQWURGXomRGHQRYRVSURFHVVRVRXDOWHUDomRGRVTXHMiH[LVWHPH
DVVHJXUDRÀX[RGHLQIRUPDo}HVSDUDRVGHPDLVHOHPHQWRVOLJDGRVDRSURMHWR
x Black belt VmR RV PHPEURV GD HTXLSH FRP H[SHULrQFLD H FRQKHFLPHQWRV GH OLGHUDQoD JHVWmR
equipes e projetos Lean Seis Sigma. Em alguns casos dedicam-se somente para projetos. Eles
lideram a equipe e fornece-lhes a formação necessária para os projetos. Há também o Master
Black BeltTXHSRVVXLYDVWDH[SHULrQFLDHFRQKHFLPHQWRGDPHWRGRORJLD
x Green beltpUHVSRQViYHOSRUOLGHUDUHTXLSHVQDFRQGXomRGHSURMHWRVIXQFLRQDLV
x Yellow beltVXSHUYLVLRQD D XWLOL]DomR GDV IHUUDPHQWDVQD URWLQD GD HPSUHVDH H[HFXWDSURMHWRV
mais focados e de desenvolvimento mais rápido.
x :KLWH beltH[HFXWDRSHUDo}HVGHURWLQDGDHPSUHVDTXHLUmRJDUDQWLUDPDQXWHQomRGRVUHVXOWDGRV
obtidos no processo.
118
INTERFACE TECNOLÓGICA - v.5 - n.1 - 2008
Estudo de caso
$HPSUHVDHVWXGDGDpVLWXDGDHP$UDUDTXDUDLQWHULRUGH6mR3DXORQHVWDXQLGDGHVmRSURGX]LGRV
HTXLSDPHQWRVSDUDDWHQGHUDGHPDQGDGRVPDLVLPSRUWDQWHVVHWRUHVGHLQIUDHVWUXWXUDGRSDtVWDLV
FRPRJHUDomRGHHQHUJLDWUDQVSRUWHPHWURIHUURYLiULRPRYLPHQWDomRHOHYDQWDPHQWRGHPDWHULDLV
FLPHQWRHPLQHUDomRSRUWXiULRVLGHUXUJLDHTXLSDPHQWRVGHSURFHVVRSHWUyOHRSHWURTXtPLFRVSDSHO
e celulose e serviços de usinagem e caldeiraria pesada. A divisão da empresa analisada é o ramo de
PHWDOXUJLDGHHTXLSDPHQWRVSURMHWRVHPRQWDJHQV
,GHQWL¿FDomRGRSUREOHPD
$WXDOPHQWHRDWUDVRQRSURFHVVRGHDEDVWHFLPHQWRpH[FHVVLYRHFRQVHTXHQWHPHQWHWHPLQÀXHQFLDGR
GUDVWLFDPHQWH R SURFHVVR SURGXWLYR $SyV UHDOL]DGR XP OHYDQWDPHQWR HP DOJXPDV REUDV VHQGR
XWLOL]DGDV FRPR DPRVWUDJHP SRGHVH REVHUYDU XP DWUDVR GH DWp GLDV QR DEDVWHFLPHQWR GH
produtos e matérias primas para a fábrica.
2REMHWLYRHVWDEHOHFLGRpUHGX]LURDWUDVRQRSURFHVVRGHDEDVWHFLPHQWRSDUDGLDVWHQGRDPpGLD
SUy[LPDGH]HURRXVHMDHQWUHGLDVRXGLDVGDGDWDGDXWLOL]DomRGDPDWpULDSULPDSHODXQLGDGH
IDEULO'HQWURGHVVDGLVWULEXLomRRREMHWLYRpFHQWUDURSURFHVVRHPXPDYDULDELOLGDGHDFHLWiYHOGH
VLJPDRXVHMDQRPtQLPRGHGRVDEDVWHFLPHQWRVGHQWURGDIDL[DGHDGLDVGDGDWDD
VHUXWLOL]DGR3DUDDWLQJLUHVVHREMHWLYRVHUmRXWLOL]DGDVWpFQLFDVGRLean (Redução de OHDGWLPH) e do
6HLV6LJPDUHGXomRGHYDULDELOLGDGHGHIRUPDFRQMXQWDXWLOL]DQGRRTXHFDGDIHUUDPHQWDDSUHVHQWD
de melhor.
2VPRWLYRVGRSURMHWRVmR
Optou-se por utilizar o conceito de OHDGWLPH como linha base de medição dos processos de
abastecimento. /HDGWLPHWHPSRGHFLFORpRWHPSRGHFRUULGRHQWUHDDGRomRGHXPDSURYLGrQFLDH
sua concretização.
A redução dos tempos envolvidos nos processos de produção é um fator importante para aumentar a
ÀH[LELOLGDGH8WLOL]DVHOHDGWLPH de abastecimento para o tempo entre a colocação de uma solicitação
GHFRWDomRGHXPDPDWpULDSULPDHDHQWUHJDGH¿QLWLYDGHVVHPDWHULDOHPFRQIRUPLGDGHSDUDDXQLGDGH
que irá utilizá-la.
119
INTERFACE TECNOLÓGICA - v.5 - n.1 - 2008
Implantação
3DUDDHODERUDomRGHVWHSURMHWRIRLIRUPDGRXPWLPHFRPSRVWRGDVHJXLQWHIRUPD
x &KDPSLRQ PHPEUR GD GLUHWRULD GD HPSUHVD UHVSRQViYHO SRU JDUDQWLU R VXSRUWH QHFHVViULR DR
projeto.
x 3DWURFLQDGRUHVJHUHQWHVGDViUHDVHQYROYLGDVUHVSRQViYHLVSRUGH¿QLUDVPHWDVHWDPEpPSHOD
participação e integração de sua equipe ao projeto.
x Mentor/Black BeltUHVSRQViYHOSHODRULHQWDomRGRWLPHQRXVRGDVIHUUDPHQWDV/HDQ6HLV6LJPD
e pela revisão do projeto.
x 0HPEURVFRPSRVWRSRURQ]HSHVVRDVGHWRGDVDViUHDVHQYROYLGDVTXHVHUmRUHVSRQViYHLVSHOD
operacionalização do projeto e por sugerir as melhorias necessárias no mesmo.
2SURMHWRWHYHLQtFLRHPGH]HPEURGHHVHHVWHQGHXDWpRXWXEURGH1RSULQFtSLRDPDLRU
GL¿FXOGDGH HQFRQWUDGD SDUD D LPSODQWDomR IRL QD FROHWD GH GDGRV SDUD D SULPHLUD PHQVXUDomR GR
SUREOHPDXPDYH]TXHDVSHVVRDVGHXPDIRUPDJHUDOQmRVHVHQWHPjYRQWDGHTXDQGRSHUFHEHP
que o processo em que estão envolvidas passa a ser medido e analisado de uma forma mais profunda
H GHWDOKDGD $OpP GLVVR D VLPSOHV SHUFHSomR GH PXGDQoDV QRV SURFHGLPHQWRV WDPEpP FDXVD
LQVHJXUDQoDHFRQVHTXHQWHPHQWHJHUDUHVLVWrQFLDSRUSDUWHGDVPHVPDV
+RXYHWDPEpPDGL¿FXOGDGHHPFRQVHJXLUTXHYiULRVVHWRUHVVHUHXQLVVHPSDUDPDSHDUXPSURFHVVR
TXH OKHV VHMD FRPXP $V iUHDV WHQGHP D JHULU VHXV SURFHVVRV GH XPD IRUPD LQGLYLGXDOL]DGD
FRPSURPHWHQGRSRUYH]HVRSODQHMDPHQWRGDVGHPDLViUHDVHQYROYLGDV2SURMHWRFRQWRXFRPR
WRWDOHLUUHVWULWRDSRLRGDDOWDGLUHomRDOpPGHWHUFUHGLELOLGDGHHPWRGRVRVQtYHLVGDHPSUHVDIDWRUHV
determinantes para o sucesso do mesmo.
Etapas do Projeto
2SURMHWRIRLGLYLGLGRHPHWDSDVGHWUDEDOKRSRUPHLRGDPHWRGRORJLD'0$,&TXHVHEDVHLDHP
FLQFRHWDSDV'H¿QLomR0HGLomR$QiOLVH0HOKRULD,PSURYHPPHQW) e Controle. Essas etapas serão
detalhadas a seguir.
x 'H¿QLomRREVHUYRXVHDWUDYpVGHPHGLGRUHVGHGHVHPSHQKRLQWHUQRVGDHPSUHVDTXHRSURFHVVR
de abastecimento da mesma vinha apresentando atrasos para a fabricação. No mapa de processo
o abastecimento inicia no momento que o planejamento emite a requisição de compra e termina
quando o setor de qualidade estabelece a conformidade dos requisitos da matéria prima. Este
SURFHGLPHQWRpGHPRQVWUDGRQD,OXVWUDomR
120
INTERFACE TECNOLÓGICA - v.5 - n.1 - 2008
,OXVWUDomR0DSDGRSURFHVVRGHDEDVWHFLPHQWR
)RQWH(PSUHVD;
x 0HGLomRIRUDPHVFROKLGRVRVSURMHWRVRQGHIRUDPLGHQWL¿FDGRVRVDWUDVRVHQWUHDGDWDGHHQWUHJD
dos fornecedores e a data de utilização para a produção. O primeiro levantamento apontou os
VHJXLQWHVUHVXOWDGRVGDWDEHOD
2VSURFHVVRVQmRVmRFHQWUDGRVHFRPGLVWULEXLo}HVHPWHUPRVGHDEDVWHFLPHQWRPXLWRGLVSHUVDV
$SyVID]HUDDQiOLVHHVWDWtVWLFDGRVGDGRVHDXWLOL]DomRGRVRIWZDUH0,1,7$%YHUVmRREVHUYRX
VHTXHDVPHGLGDVHPWHUPRVGHVLJPDPpWULFDHVWmRUD]RDYHOPHQWHGLVWDQWHVGDPHWDGHVLJPD+i
FDVRVGHYDORUHVQHJDWLYRVRTXHLQGLFDSURFHVVRVWRWDOPHQWHIRUDGRVOLPLWHVGHHVSHFL¿FDo}HVGD
121
INTERFACE TECNOLÓGICA - v.5 - n.1 - 2008
IDL[DGHjGLDV
1D,OXVWUDomRWHPVHDUHSUHVHQWDomRJUi¿FDGDPHGLomRGRDEDVWHFLPHQWRGRSURMHWRGHXPDSRQWH
URODQWHGHQRPLQDGD+3
,OXVWUDomR'LVWULEXLomRDEDVWHFLPHQWRGDSRQWHURODQWH
)RQWH(PSUHVD;
x $QiOLVHRVGDGRVOHYDQWDGRVLQGLFDPTXHKiXPDGLVSHUVmRPXLWRJUDQGHQRTXHVHUHIHUHDRV
SUD]RVGHDEDVWHFLPHQWR$VVLPFRPRQXPPHVPRSURMHWRFRVQWDWRXVHDQWHFLSDo}HVQDHQWUHJD
GH DOJXQV FRPSRQHQWHV DFRQWHFHUDP DWUDVRV FRQVLGHUiYHLV HP RXWURV R TXH JHUD XPD VpULH
GH GHVHTXLOtEULRV H FRQWUDWHPSRV QR SODQHMDPHQWR H QD H[HFXomR GR SURMHWR FRPSURPHWHQGR
SRU¿PRFXPSULPHQWRGRVSUD]RVDFRUGDGRVFRPRVFOLHQWHV&RQFOXLVHTXHDVFDXVDVGHVWHV
GHVFRPSDVVRVHUDPEDVLFDPHQWHDIDOWDGHXPFRQWUROHPDLVHIHWLYRGHFDGDHWDSDGRSURFHVVR
DOpPGDGL¿FXOGDGHGHVHFRQVHJXLUIRUQHFHGRUHVDSWRVDWUDEDOKDUHPXPDVLQWRQLDPDLVD¿QDGD
com a empresa.
x 0HOKRULDVRVROXomRHQFRQWUDGDIRLXWLOL]DUDMXQomRGR/HDQH6HLV6LJPD'RLean foi utilizado
RFRQFHLWRGHUHGXomRGROHDGWLPHGHDEDVWHFLPHQWRGLQkPLFRRXVHMDRSURFHVVRpGLYLGLGR
HPWUrVHWDSDVTXHVmRSODQHMDPHQWRFRPSUDVHIRUQHFHGRUHVTXHSDVVDPDVHUPRQLWRUDGRV
quanto ao cumprimento de seus prazos. Cada etapa terá o seu sigma próprio e todos consolidados
LQGLFDPRVLJPDGRDEDVWHFLPHQWRGRSURMHWR1D,OXVWUDomRWHPVHRSURFHVVRDQWHULRUVHPD
utilização do conceito de lead-time. Esse processo não apresenta uma linha de base de tempo de
UHIHUrQFLD
122
INTERFACE TECNOLÓGICA - v.5 - n.1 - 2008
,OXVWUDomR6LVWHPDVHPLQWHUDomR
)RQWH(PSUHVD;
1D LOXVWUDomR p DSUHVHQWDGR R SURMHWR GH PHOKRULD FRP D LQWHJUDomR GR FRQFHLWR /HDQ /HDG
WLPHdinâmico com IHHGEDFN do tempo de compra e tempo de entrega do fornecedor. Esses valores
FRPS}HPROHDGWLPH dinâmico.
,OXVWUDomR6LVWHPDFRPIHHGEDFNSDUDOHDGWLPHGLQkPLFR
)RQWH(PSUHVD;
1D,OXVWUDomRREVHUYDVHHPWHUPRVGHPHGLomRGHGHVHPSHQKRTXHFDGDHWDSDGRDEDVWHFLPHQWR
SODQHMDPHQWRHVXSULPHQWRVWHUiXPFiOFXORGHVLJPDHVSHFt¿FRHIRUPDUiRVLJPDGHDEDVWHFLPHQWR
123
INTERFACE TECNOLÓGICA - v.5 - n.1 - 2008
,OXVWUDomR&RPSRVLomRGRVLJPDGHDEDVWHFLPHQWR
)RQWH(PSUHVD;
,OXVWUDomR6LVWHPD(53DMXVWDGRFRPROHDGWLPHGHDEDVWHFLPHQWR
)RQWH(PSUHVD;
124
INTERFACE TECNOLÓGICA - v.5 - n.1 - 2008
'HVVDIRUPDpSRVVtYHOSRUH[HPSORDiUHDGHVXSULPHQWRVUHDOL]DUDVFRPSUDVGHDFRUGRFRPR
OHDGWLPH de abastecimento e de compra de determinado componente a ser utilizado na fabricação
dos equipamentos.
x &RQWUROHFRPDIHUUDPHQWDDFLPDRFRQWUROHGRSURFHVVRSDVVDDVHUIHLWRHPFDGDHWDSDHRV
UHVXOWDGRVDSRQWDGRVHPWHPSRUHDOSRVVLELOLWDQGRTXHDViUHDVWRPHPXPDDomRLPHGLDWDPHQWH
TXDQGR VH YHUL¿FD TXH DOJXP SUREOHPD DFRQWHFH PLQLPL]DQGR DVVLP D SRVVLELOLGDGH GH QmR
FXPSULPHQWRGRVSUD]RVSODQHMDGRV'H¿QLVHTXHRVLJPDDFHLWiYHOSDUDRVSURMHWRVpQRPtQLPR
GHVLJPDRXVHMDDFHUWRVHPDEDVWHFLPHQWRVGHSHORPHQRV
Resultados obtidos
'HYLGR j FRPSOH[LGDGH GRV HTXLSDPHQWRV SURGX]LGRV SHOD HPSUHVD TXH SRGHP GHPRUDU DWp
PHVPR DQRV SDUD VHUHP FRQFOXtGRV D PHWD HVWLSXODGD GH QR PtQLPR GRV DEDVWHFLPHQWRV
GHQWURGRSUD]RGHDGLDVGDGDWDHIHWLYDPHQWHQHFHVViULDDLQGDQmRIRLDWLQJLGDSRLVDOJXQV
projetos já estavam em andamento quando a ferramenta foi implantada. Com a utilização da nova
IHUUDPHQWDSHORGHSDUWDPHQWRGHVXSULPHQWRVGDHPSUHVDpFODUDPHQWHSHUFHSWtYHODUHGXomRQRV
SUD]RVGHDEDVWHFLPHQWRQRVQRYRVSURMHWRVRTXHJDUDQWHTXHDPHWDVHUiEUHYHPHQWHDOFDQoDGD
HYLGHQFLDQGR DVVLP HVWH SURMHWR FRPR QHFHVViULR SDUD GDU j HPSUHVD D FDSDFLGDGH GH JHULU VHXV
SURFHVVRVGHXPDIRUPDH¿FD]UHVXOWDQGRQRDSULPRUDPHQWRGHWRGDVXDFDGHLDSURGXWLYDID]HQGR
com que a organização cumpra pontualmente os compromissos assumidos em seus contratos e por
FRQVHTrQFLDDJUHJXHYDORUjVXDLPDJHPSHUDQWHVHXVFOLHQWHVHRPHUFDGRHPJHUDO
CONCLUSÃO
3RUPHLRGDDQiOLVHGRPDWHULDOGHSHVTXLVDIRLSRVVtYHOYHUL¿FDUTXHH[LVWHPDOJXPDVVHPHOKDQoDV
HQWUH DV GXDV PHWRGRORJLDV 1R HQWDQWR HODV SRVVXHP FDUDFWHUtVWLFDV GLVWLQWDV H VXD HVFROKD GHYH
OHYDUHPFRQVLGHUDomRDFXOWXUDGDHPSUHVDUHFXUVRVGLVSRQtYHLVHUHVXOWDGRVGHVHMDGRV$DYDOLDomR
das características de cada programa de melhoria visando a integração do Lean com o Seis Sigma
QRVPRVWUDTXHFDGDVLVWHPDWHPVXDVSDUWLFXODULGDGHVSRVLWLYDVHQHJDWLYDVTXHGHYHPVHUOHYDGDV
HPFRQWDSDUDDLQWHJUDomR(PWHPSRVGHFRQFRUUrQFLDDFLUUDGDDH[FHOrQFLDGDJHVWmRDTXDOLGDGH
GHH[HFXomRHDYLVmRGHORQJRSUD]RSRGHPGHWHUPLQDUDVREUHYLYrQFLDGRQHJyFLR2/HDQ6HLV
6LJPDpXPPpWRGRHYROXWLYRGHFRQFHLWRVGHSURGXomRHQ[XWDHGDJHVWmRGDTXDOLGDGHWRWDOVXDV
DSOLFDo}HVVmRIHLWDVSRUPHLRGHDQiOLVHVHFRQWUROHVHVWDWtVWLFRVGHSURFHVVRVEXVFDGHPHOKRULDV
HPTXDOLGDGHHDXPHQWRGHFRPSHWLWLYLGDGH2PpWRGRSURS}HDQDOLVDUHSUHYHUDVYDULDELOLGDGHV
PHOKRUDUDTXDOLGDGHGRVSURGXWRVHVHUYLoRVDXPHQWDUDYHORFLGDGHGRVSURFHVVRVEXVFDUDVDWLVIDomR
dos consumidores e com isso alavancar os negócios empresariais.
(VWH WUDEDOKR IRFDOL]RX RV DVSHFWRV WpFQLFRV GH LPSOHPHQWDomR GD ¿ORVR¿D GD PDQXIDWXUD HQ[XWD
MXQWDPHQWHFRPDPHWRGRORJLD6HLV6LJPDHPXPDLQG~VWULDPHWDO~UJLFDLQVWDODGDHP$UDUDTXDUD
63$WUDYpVGDDSOLFDomRGR'0$,&HGDVIHUUDPHQWDVXWLOL]DGDVQDPDQXIDWXUDHQ[XWDIRLSRVVtYHO
GHWHUPLQDUHTXDQWL¿FDURVSULQFLSDLVGHIHLWRVHHPTXDLVSURFHVVRVKDYLDPDLVGHVSHUGtFLRVFRPR
WDPEpPDQDOLVDUDVFDXVDVGRVGHIHLWRVSDUDRHVWDEHOHFLPHQWRGHDo}HVGHPHOKRULD&RPHVVHHVWXGR
SRGHVHREVHUYDUDVLWXDomRGDHPSUHVDDQWHVGDLPSOHPHQWDomRHRVSURFHVVRVGDPHVPDWRUQDQGR
125
INTERFACE TECNOLÓGICA - v.5 - n.1 - 2008
SRVVtYHODQDOLVDURVUHVXOWDGRVREWLGRVQRVSURFHVVRVSURGXWLYRVHVXDVFRQWULEXLo}HVSDUDRDXPHQWR
GDH¿FLrQFLDRSHUDFLRQDO$OpPGLVVRSRGHVHREVHUYDUDLPSRUWkQFLDGDSDUWLFLSDomRHHQWURVDPHQWR
GHYiULRVGHSDUWDPHQWRVGDHPSUHVDIDWRUPXLWRLPSRUWDQWHSDUDTXHDLPSOHPHQWDomRRFRUUDFRP
VXFHVVR$PEDVDVPHWRGRORJLDVWUD]HPJUDQGHVEHQHItFLRVjVHPSUHVDVSULQFLSDOPHQWHTXDQGRVmR
implementadas respeitando-se os conceitos e princípios de cada uma delas.
ABSTRACT
'XH WR JOREDOL]DWLRQ FRPSHWLWLRQ KDV EHFRPH PRUH DFFHQWXDWHG ,Q RUGHU WR UHPDLQ FRPSHWLWLYH
FRPSDQLHVQHHGWRVHDUFKIRURUWRGHYHORSQHZPHWKRGRORJLHVDQGWHFKQLTXHVRIPDQDJHPHQW/HDQ
6L[6LJPDUHSUHVHQWVDQLQWHJUDWHGDSSURDFKRIWZRPHWKRGRORJLHVWKDWZHUHGHYHORSHGDOWKRXJK
WKH\ FDQ EH XVHG LQGLYLGXDOO\ 6L[ 6LJPD DQG /HDQ +RZHYHU WKH DGYDQWDJHV RI WKH LQWHJUDWHG
LPSOHPHQWDWLRQRIWKHWZRDSSURDFKHVKDYHSURYHGWREHYHU\UHOHYDQW7KLVZRUNDLPHGWRGHPRQVWUDWH
WKHLPSRUWDQFHRIWKHMXQFWLRQRI/HDQ0DQXIDFWXULQJDQG6L[6LJPDPHWKRGVWRUHGXFHWKHZDVWHDQG
FRVWVLQRUGHUWRLQFUHDVHWKHTXDOLW\DQGWKHGHOLYHU\VSHHGVHUYLFHWRFXVWRPHUV)RUWKHSXUSRVHWR
DFKLHYHRXUJRDODELEOLRJUDSKLFUHVHDUFKIROORZHGE\D¿HOGUHVHDUFKZDVKHOGLQDELJVL]HFDSLWDO
JRRGVFRPSDQ\LQ$UDUDTXDUD63,WIROORZVWKDWE\DSSO\LQJWKH'0$,&DQGWRROVXVHGLQOHDQ
PDQXIDFWXULQJLVSRVVLEOHWRGHWHUPLQHDQGTXDQWLI\WKHPDMRUGHIHFWVLQZKLFKSURFHVVHVWKHUHLV
PRUHZDVWHDQGZHFDQDQDO\]HWKHFDXVHVRIGHIHFWVIRUWKHHVWDEOLVKPHQWRILPSURYHPHQWDFWLRQV
LQFUHDVLQJWKHFRPSDQ\¶VHI¿FLHQF\
KEYWORDS: /HDQ0DQXIDFWXULQJ6L[6LJPD/HDQ6L[6LJPD'0$,&
REFERÊNCIAS
&2521$'25%$1721<-&ULWLFDOVXFFHVVIDFWRUVIRUWKHVXFFHVVIXOLPSOHPHQWDWLRQRI6L[
6LJPDSURMHFWVLQ2UJDQLVDWLRQVHG'HVHQYROYLPHQWR
'$<&+2800)HUUDPHQWDVH7pFQLFDVGH*HUHQFLDPHQWR5LRGH-DQHLUR'HVHQYROYLPHQWR
)(51$1'(6 + 9 /HDQ 6L[ 6LJPD (VWXGR GR 3RWHQFLDO GH ,PSODQWDomR QD ;pUR[ ± 8QLGDGH
,QGXVWULDO1RUGHVWH'LVVHUWDomR0HVWUDGR±8QLYHUVLGDGH)HGHUDOGD%DKLD6DOYDGRU
*(25*( 0 /HDQ 6HLV 6LJPD SDUD 6HUYLoRV &RPR 8WLOL]DU 9HORFLGDGH /HDQ H 4XDOLGDGH 6HLV
6LJPDSDUD0HOKRUDU6HUYLoRVH7UDQVDo}HV6mR3DXOR'HVHQYROYLPHQWR
LEAN INSTITUTE BRASIL. 'LVSRQtYHOHPZZZOHDQRUJEU!$FHVVRHP-XQ
0,7&+(//%7KH6L[6LJPDDSSHDO(QJLQHHULQJ0DQDJHPHQW-RXUQDO6WHYHQDJH8.YQ
SIHY
2+12 7 2 6LVWHPD 7R\RWD GH 3URGXomR além da produção em larga escala. 3RUWR $OHJUH
'HVHQYROYLPHQWR
5$6,6 ' 3DSHU 2UJDQL]HUV ,QWHUQDWLRQDO $ )LFWLWLRXV 6L[ 6LJPD *UHHQ %HOW &DVH 6WXG\
'HVHQYROYLPHQWR
:(5.(0$& /HDQ6HLV6LJPD,QWURGXomRjV)HUUDPHQWDVGR/HDQ0DQXIDFWXULQJ%HOR+RUL]RQWH
'HVHQYROYLPHQWR
126