Análise da correlação do lean manufacturing com produtos modulares

José Antonio Carnevalli; Marcos Ricardo Rosa Georges; Samuel Carvalho De Benedicto; José Eduardo Rodrigues de Sousa

doi:10.5585/exactaep.2021.11316

Autores

José Antonio Carnevalli PUC - CAMPINAS https://orcid.org/0000-0003-3432-1235
Marcos Ricardo Rosa Georges PUC - CAMPINAS https://orcid.org/0000-0003-2828-6680
Samuel Carvalho De Benedicto PUC - CAMPINAS https://orcid.org/0000-0002-4591-6077
José Eduardo Rodrigues de Sousa PUC - CAMPINAS https://orcid.org/0000-0002-8027-329X

DOI:

https://doi.org/10.5585/exactaep.2021.11316

Palavras-chave:

Modularidade, Revisão de literatura, Lean Manufacturing.

Resumo

A abordagem modular tem sido aplicada com bom desempenho na indústria automobilística e nos fabricantes de computadores que tradicionalmente utilizam o Lean Manufacturing. Mas qual é o seu efeito no Lean Manufacturing? Será que a modularidade está restrita somente a estes setores? Este trabalho responde a estas questões por meio de uma revisão da literatura e do uso dos diagramas de afinidade e de árvore em conjunto com a matriz de correlação. Nos resultados verificou-se o uso da modularidade na fabricação de máquinas industriais, residência, prédios, aviões, eletrodomésticos, brinquedos, bicicleta, software entre outros. Estes resultados mostram que a modularidade pode ser aplicada em vários tipos de produtos manufaturados. Em relação ao Lean Manufacturing a modularidade tem um efeito positivo nesta aplicação ajudando a atender alguns dos objetivos do Lean como redução do lead time.

Downloads

Não há dados estatísticos.

Biografia do Autor

José Antonio Carnevalli, PUC - CAMPINAS

Pós-Doutorado em Engenharia de Produção pela Universidade de São Paulo, USP. Professor, Pesquisador do Centro de Economia e Administração, CEA, Pontifícia Universidade Católica de Campinas, PUC-Campinas, Campinas, São Paulo /Brasil. Membro do Grupo de Pesquisa em “Gestão de Operações e Serviços”. E-mail: jose.carnevalli@puc-campinas.edu.br.

Marcos Ricardo Rosa Georges, PUC - CAMPINAS

Doutor em Engenharia Mecânica pela Universidade Estadual de Campinas - UNICAMP, Professor, Pesquisador do Mestrado em Sustentabilidade da Pontifícia Universidade Católica de Campinas. Líder do Grupo de Pesquisa em “Gestão de Operações e Serviços” E-mail: marcos.georges@puc-campinas.edu.br

Samuel Carvalho De Benedicto, PUC - CAMPINAS

Doutor em Administração pela Universidade Federal de Lavras - UFLA. Professor, Pesquisador e Coordenador do Mestrado em Sustentabilidade da Pontifícia Universidade Católica de Campinas. Membro do Grupo de Pesquisa “Gestão Estratégica e Sustentabilidade”. Contatos: (19) 98281-7644 - samuel.benedicto@puc-campinas.edu.br

José Eduardo Rodrigues de Sousa, PUC - CAMPINAS

Doutor, Administração, Professor, Pesquisador do Centro de Economia e Administração, CEA, Pontifícia Universidade Católica de Campinas, PUC-Campinas, Campinas, São Paulo /Brasil. Líder do Grupo de Pesquisa “Gestão Estratégica e Sustentabilidade”. E-mail: eduardo.sousa@puc-campinas.edu.br

Referências

Acaccia, G. Bruzzone, L., & Razzoli, R. (2008). A modular robotic system for industrial applications. Assembly Automation, 28(2), 151-162. doi: https://doi.org/10.1108/01445150810863734.

Arnheiter, E.D., & Harren, H. (2005). A typology to unleash the potential of modularity. Journal of Manufacturing Technology Management, 16(7), 699- 711. doi: https://doi.org/10.1108/17410380510619923.

Arnheiter, E. D., & Harren, H. (2006). Quality management in a modular world. The TQM Magazine, 18(1), 87-96. doi: https://doi.org/10.1108/09544780610637712.

Arnheiter, E. D., & Greenland, J. E. (2008). Looking for root cause: a comparative analysis. The TQM Journal. 20(1), 18-30. doi: https://doi.org/10.1108/09544780810842875.

Baldwin, C.Y., & Clark K.B. (2000). Design rules. Massachusetts: MIT Press.

Barbosa, G. F., Carvalho, J., & Filho, E. V. G. (2014). A proper framework for design of aircraft production system based on lean manufacturing principles focusing to automated processes. The International Journal of Advanced Manufacturing Technology, 72(9-12), 1257-1273. doi: https://doi.org/10.1007/s00170-014-5729-3.

Bevilacqua, M., Ciarapica, F. E., De Sanctis, I., Mazzuto G., & Paciarotti, C. (2015). A changeover time reduction through an integration of lean practices: a case study from pharmaceutical sector. Assembly Automation, 35(1), 22-34. doi: https://doi.org/10.1108/AA-05-2014-035.

Brookfield, J., Liu, R.J., & MacDuffie, J.P. (2008). Taiwan's bicycle industry A - Team battles Chinese competition with innovation and cooperation. Strategy & Leadership, 36(1), 14-19. doi: https://doi.org/10.1108/10878570810840643.

Cagatay Iris, & Ufuk Cebeci. (2014). Analyzing relationship between ERP utilization and lean manufacturing maturity of Turkish SMEs, Journal of Enterprise Information Management, 27(3), 261-277. doi: https://doi.org/10.1108/JEIM-12-2013-0093.

Carmignani, G., & Zammori, F. (2015). Lean thinking in the luxury-fashion market evidences from an extensive industrial Project. International Journal of Retail & Distribution Management, 43(10/11), 988-1012. doi: https://doi.org/10.1108/IJRDM-07-2014-0093.

Carnevalli, J. A., Salerno, M. S., & Miguel, P. A. C. (2010). Proposta de um levantamento de campo sobre a adoção da modularidade em empresas do setor automotivo visando investigar aspectos sobre a sua aplicação. (Relatório científico do pós-doutorado para a FAPESP) São Paulo, SP, Poli, USP.

Carvalho, M. M., Paladini, E. P., Bouer, G., Ferreira, J.J.D.A., Miguel, P. A. C., Samohyl, R. W., & Rotondaro, R.G. (2012). Gestão da qualidade: teoria e casos. Rio de Janeiro: Elsevier.

Cauchick Miguel, P. A., & Pires, S. R. I. (2006). A case study on modularity in product development and production within the auto industry. International Journal of Automotive Technology and Management, 6(3), 315-330. doi: https://doi.org/10.1504/IJATM.2006.012123.

Chaplin, L., Heap J., & O’rourke, S. T. J. (2016). Reflective practice could “lean lite” be the cost effective solution to applying lean manufacturing in developing economies? International Journal of Productivity and Performance Management, 65(1), 126-136. doi: https://doi.org/10.1108/IJPPM-02-2015-0034,

Collins, R., Bechler, K., & Pires, S. R.I. (1997). Outsourcing in the automotive industry: from JIT to Modular Consortia. European Management Journal, 15(5), 498-508. doi: https://doi.org/10.1016/S0263- 2373(97)00030-3.

Connolly, C. (2008). Prosthetic hands from Touch Bionics. Industrial Robot: An International Journal, 35(4), 290-293. doi: https://doi.org/10.1108/01439910810876364.

Danese, P., & Romano, P. (2004). Improving inter-functional coordination to face high product variety and frequent modifications. International Journal of Operations & Production Management, 24(9), 863-885. doi: https://doi.org/10.1108/01443570410552090.

De Mello, A. M., & Marx, R. (2007). Innovative capacity maintenance by automakers in a product development outsourcing scenario: the case of VW in Brazil. International Journal of Automotive Technology and Management, 7(2/3), 200-215. doi: https://doi.org/10.1504/IJATM.2007.014975.

Doran, D. (2002). Manufacturing for synchronous supply: a case study of Ikeda Hoover Ltd. Integrated Manufacturing Systems, 13(1), 18-24. doi: http://doi.org/10.1108/09576060210411477.

Doran, D. (2005). Supplying on a modular basis: an examination of strategic issues. International Journal of Physical Distribution & Logistics Management, 35(9), 654-663. doi: http://doi.org/10.1108/09600030510632023.

Fong, A.C.M., & Hui S.C. (2006). A virtual electronic trading system for business-to-business e-commerce. Kybernetes. 35(6), 865-879. doi: https://doi.org/10.1108/03684920610662674.

Forno, A. J. D., Forcellini, F.A., Kipper, L.M., & Pereira, F.A. (2016). Method for evaluation via benchmarking of the lean product development process. Benchmarking: An International Journal, 23(4), 792-816. doi: https://doi.org/10.1108/BIJ-12-2013-0114.

Fredriksson, P. (2006a). Operations and logistics issues in modular assembly processes: cases from the automotive sector. Journal of Manufacturing Technology Management, 17(2), 168-186. doi: https://doi.org/10.1108/17410380610642250.

Fredriksson, P. (2006b). Cooperation and conflict in modular production and supplier parks: the case of Volvo Cars' modular assembly system. International Journal of Automotive Technology and Management, 6(3), 298-314. doi: https://doi.org/10.1504/IJATM.2006.012122.

Frigant, V., & Lung, Y. (2002) Geografical proximity and supplying relationships in modular production. International Journal of Urban and Regional Research, 26(4), 742-755. doi: http://doi.org/10.1111/1468- 2427.00415.

Gabrieli, L., Cortimiglia, M., & Ribeiro, J.L. (2007). Modelagem e avaliação de um sistema modular para gerenciamento de informação na Web. Ciência da Informação. 36(1), 35-53. doi: http://dx.doi.org/10.1590/S0100-19652007000100003.

Gong, Y., & Janssen, M. (2015). Demystifying the benefits and risks of lean service innovation: a banking case study. Journal of Systems and Information Technology, 17(4), 364-380. doi: https://doi.org/10.1108/JSIT-03-2015-0019.

Gu, P., & Sosale, S. (1999). Product modularization for life cycle engineering. Robotics

and Computer Integrated Manufacturing, 15(5), 387-401. doi: https://doi.org/10.1016/S0736-5845(99)00049-6.

He, D.W., & Kusiak, A. (1998). Designing an assembly line for modular products. Computers & Industrial Engineering, 34(1), 37-52.

Hoek, R.I.V., & Weken, H.A.M. (1998). The impact of modular production on the dynamics of supply chains. The International Journal of Logistics Management, 9(2), 35-50. doi: https://doi.org/10.1108/09574099810805825.

Holmes, J. (2004). Re-scaling collective bargaining: union responses to restructuring in the North American auto industry. Geoforum, 35(1), 9-21. doi: https://doi.org/10.1016/j.geoforum.2003.06.001.

Jasti, N. V. K., & Sharma, A. (2014). Lean manufacturing implementation using value stream mapping as a tool. International Journal of Lean Six Sigma. 5(1), 89-116. doi: https://doi.org/10.1108/IJLSS-04-2012-0002.

Kumar Br, R., Sharma, M.K., & Agarwal, A. (2015). An experimental investigation of lean management in aviation. Journal of Manufacturing Technology Management. 26(2), 231-260. doi: https://doi.org/10.1108/JMTM-12-2013-0174.

Lau, A. K. W., & Yam, R. C. M. (2005). A case study of product modularization on supply chain design and coordination in Hong Kong and China. Journal of Manufacturing Technology Management, 16(4), 432-446. doi: https://doi.org/10.1108/17410380510594516.

Lau, A. K. W., Yam, R.C.M., & Tang, E.P.Y. (2007). Supply chain product co-development, product modularity and product performance: Empirical evidence from Hong Kong manufacturers. Industrial Management & Data Systems, 107(7), 1036-1065. doi: https://doi.org/10.1108/02635570710816739.

Lee, W. B., Lau, H., & Tam, S. (2001). A fuzzy analytic hierarchy process approach in modular product design. Expert Systems, 18(1), 32-42, 2001. doi: https://doi.org/10.1111/1468-0394.00153.

Lohse, N., Ratchev, S., & Valtchanov, G. (2004). Towards Web-enabled design of modular assembly systems. Assembly Automation, 24(3), 270-279. doi: https://doi.org/10.1108/01445150410549764.

Lopes, R. B., Freitas, F., & Sousa, I. (2015). Application of lean manufacturing tools in the food and beverage industries. Journal of Technology Management & Innovation, 10(1), 120-130. doi: http://dx.doi.org/10.4067/S0718-27242015000300013.

Ma, J., & Kremer, G. E. O. (2016). A systematic literature review of modular product design (MPD) from the perspective of sustainability. The International Journal of Advanced Manufacturing Technology. 86(5-8), 1509–1539.

Machado, A. G. C, & Moraes, W. F. G. (2008) Estratégias de customização em massa implementadas por empresas brasileiras. Produção, 18(1), 170-183. doi: http://dx.doi.org/10.1590/S0103-65132008000100013.

Marconi, M. D. A., & Lakatos, E. M. (2007). Técnicas de pesquisa: planejamento e execução de pesquisas, amostragens e técnicas de pesquisas, elaboração, análise e interpretação de dados. (6a. ed.). São Paulo: Atlas.

Martins, P. G., & Laugeni, F. P. (2010). Administração da produção. São Paulo: Saraiva.

Marx, R., Zilbovicius, M., & Salerno, M. S. (1997). The modular consortium in a new VW truck plant in Brazil: new forms of assembler and supplier relationship. Integrated Manufacturing Systems, 8(5), 292-298. doi: https://doi.org/10.1108/09576069710179742.

Moeckel, R., Jaquier, C., Drapel, K., Dittrich, E., Upegui, A., & Ijspeert, A.J. (2006). Exploring adaptive locomotion with YaMoR, a novel autonomous modular robot with bluetooth interface. Industrial Robot: An International Journal, 33(4), 285-290. doi: https://doi.org/10.1108/01439910610667908.

Mondragon, C. E. C., Mondragon, A.E.C, & Miller, R. (2006). Modularity, open architecture and innovation: an automotive perspective. International Journal of Automotive Technology and Management, 6(3), 346 – 363. doi: https://doi.org/10.1504/IJATM.2006.012125.

Moore, J. F. (1999). Civil integrated modular avionics - a longer-term view. Aircraft Engineering and Aerospace Technology: An International Journal, 71(6), 550-557. doi: https://doi.org/10.1108/00022669910303702.

Morgan, J. M., & Liker, J. K. (2006). The TOYOTA product development system: integrating people, process and technology, New York: Productivity Press apud Mund, K., Pieterse, K., & Cameron, S. (2015). Lean product engineering in the South African automotive industry. Journal of Manufacturing Technology Management, 26(5), 703-724. doi: https://doi.org/10.1108/JMTM-05-2013-0062.

Morris, D., & Donnelly, T. (2006). Are there market limits to modularisation? International Journal of Automotive Technology and Management, 6(3), 262- 275. doi: http://doi.org/10.1504/IJATM.2006.012120.

Mund, K., Pieterse, K., & Cameron, S. (2015). Lean product engineering in the South African automotive industry. Journal of Manufacturing Technology Management, 26(5), 703-724. doi: https://doi.org/10.1108/JMTM-05-2013-0062.

Nahmens, I., & Ikuma L. H. (2012). Effects of lean construction on sustainability of modular homebuilding. Journal of Architectural Engineering. 18(2), 155-163.

Nepal, B., Monplaisir, L., & Famuyiwa, O. (2012). Matching product architecture with supply chain design. European Journal of Operational Research. 216(2), 312-325. doi: https://doi.org/10.1016/j.ejor.2011.07.041.

O'gragy, P., & Liang W. Y. (1998). An object oriented approach to design with modules. Computer Integrated Manufacturing Systems, 11(4), 267-283. doi: https://doi.org/10.1016/S0951-5240(98)00024-X.

Olivella, J., & Gregorio, R. (2015). A case study of an integrated manufacturing performance measurement and meeting system. Journal of Manufacturing Technology Management, 26(4), 515-535. doi: https://doi.org/10.1108/JMTM-09-2012-0089.

Orsato, R. J., & Wells, P. (2007). U-turn: the rise and demise of the automobile industry. Journal of Cleaner Production, 15(11-12), 994-1006. doi: https://doi.org/10.1016/j.jclepro.2006.05.019.

Ohfuji, T., Ono, M, & Akao, Y. (1997). Métodos de desdobramento da qualidade (Vol. 2). Belo Horizonte: Fundação Christiano Ottoni.

Pandremenos, J., Paralikas, J., & Chryssolouris, G. (2009). Modularity concepts for the automotive industry: A critical review. CIRP Journal of Manufacturing Science and Technology, 1(3), 148-152. doi: https://doi.org/10.1016/j.cirpj.2008.09.012.

Pérez, M. P., & Sánchez, A. M. (2000). Lean production and supplier relations: a survey of practices in the Aragonese automotive industry. Technovation, 20(12), 665-676. doi: https://doi.org/10.1016/S0166-4972(00)00011-0.

Pires, S. R. I. (1998). Managerial implications of the modular consortium model in a Brazilian automotive plant. International Journal of Operations & Production Management, 18(3), 221-232. doi: https://doi.org/10.1108/01443579810368290.

Pires, S. R. I. (2002). New productive systems in the automotive industry: the current situation of three innovative plants Brazil. Internal Journal of Automotive Technology and Management, 2(1), 46-62. doi: https://doi.org/10.1504/IJATM.2002.000056.

Pires, S. R. I., & Sacomano, M., Neto. (2010). Características estruturais, relacionais e gerenciais na cadeia de suprimentos de um condomínio industrial na indústria automobilística. Produção, 20(2), 172-185. doi: https://doi.org/10.1590/S0103-65132010005000032.

Ranky, G. N. (2007). Mobile robot sensor and networking design to enable cooperative behavior. Industrial Robot: An International Journal, 34(1), 21-25. doi: https://doi.org/10.1108/01439910710718405.

Rezende, E. M., & Gouveira, A. M. C. (2006). Sistemas de estacionamento vertical modulado em estrutura metálica. REM: Revista Escola de Minas, 59(3), 279-284. doi: http://dx.doi.org/10.1590/S0370-44672006000300005.

Salerno, M. S. (2001). The characteristics and the role of modularity in the automotive business. International Journal of Automotive Technology and Management, 1(1), 92-107. doi: https://doi.org/10.1504/IJATM.2001.000029.

Salerno, M. S., Camargo, O.S., & Lemos, M.B. (2008). Modularity ten years after: an evaluation of the Brazilian experience. International Journal of Automotive Technology and Management, 8(4), 373-381. doi: https://doi.org/10.1504/IJATM.2008.020309.

Sanchez, R., & Collins, R. P. (2001). Competing - and learning - in modular markets. Long Range Planning, 34(6), 645-667. doi: https://doi.org/10.1016/S0024-6301(01)00099-1.

Shibata, T., Yano, M., & Kodama, F. (2008). Empirical analysis of evolution of product architecture Fanuc numerical controllers from 1962 to 1997. Research Policy, 34(1), 13-31. doi: https://doi.org/10.1016/j.respol.2004.09.011.

Shuenemann, M., Grosser, V., Leutenbauer, R., Bauer, G., Schaefer, W., & Reichl, H. (1999). A highly flexible design and production framework for modularized microelectromechanical systems. Sensors and Actuators - A, physical, 73(1-2), 153-168. doi: https://doi.org/10.1109/MEMSYS.1998.659825.

Spath, D., & Baumeister M. (2001). Synchronisation of material flow and assembly in hybrid and modular systems. Assembly Automation, 21(2), 152-157. doi: https://doi.org/10.1108/01445150110388504.

Veloso, F., & Fixson, S. (2001). Make-Buy decisions in the auto industry: new perspectives on the role of the supplier as an innovator. Technological Forecasting and Social Change, 67(2-3), 239-257. https://doi.org/10.1016/S0040-1625(00)00092-5.

Virk, G. S., Muscato, G., Semerano, A., Armanda, M., & Warren, H.A. (2004). The CLAWAR project on mobile robotics. Industrial Robot: An International Journal, 31(2), 130-138. doi: https://doi.org/10.1108/01439910410522801.

Voordijk, H., Meijboom, B., & Haan, J. D. (2006). Modularity in supply chains: a multiple case study in the construction industry. International Journal of Operations & Production Management. 26(6), 600-618. doi: https://doi.org/10.1108/01443570610666966.

Womack, J. P., Jones, D. T., & Roos.D. (1992). A máquina que mudou o mundo, (5a ed.). Rio de Janeiro: Editora Campus.

Yigit, A., Ulsoy, A.G., & Allahverdi, A. (2002). Optimizing modular product design for reconfigurable manufacturing. Journal of Intelligent Manufacturing, 13(4), 309-316.

Zhang, G.W., Zhang, S.C., & Xu, Y.S. (2002). Research on flexible transfer line schematic design using hierarchical process planning. Journal of Materials Processing Technology, 129(1-3), 629-633. doi: https://doi.org/10.1016/S0924-0136(02)00670-2.