Melhorias do lean manufacturing na gestão de manutenção : estudo de caso.

Abstract

Este estudo avalia a implementação das ferramentas do Lean Manufacturing no setor de manutenção de uma planta de envase de Gás Liquefeito de Petróleo (GLP). O Lean Manufacturing, baseado no Sistema Toyota de Produção, busca eliminar desperdícios, otimizar processos e maximizar o valor para o cliente. A pesquisa foca em quatro ferramentas principais: padronização de atividades, Manutenção Produtiva Total (TPM), 5S e Kanban. Adotou-se uma abordagem mista, combinando indicadores quantitativos (MTTR, MTBF, OEE, tempo de atendimento de ordens de serviço e níveis de estoque) com avaliações qualitativas sobre a adesão dos colaboradores e práticas organizacionais. Os resultados demonstraram redução de paradas, maior eficiência de manutenção, aumento da disponibilidade de ativos e maior confiabilidade dos processos. A integração das ferramentas Lean Manufacturing promoveu melhoria contínua, engajamento dos funcionários e disciplina operacional, evidenciando impactos positivos na excelência operacional da planta de envase de GLP.

This study evaluates the implementation of Lean Manufacturing tools in the maintenance department of a Liquefied Petroleum Gas (LPG) filling plant. Lean Manufacturing, rooted in the Toyota Production System, aims to eliminate waste, optimize processes, and maximize customer value. The research focuses on four key Lean tools: standardization of activities, Total Productive Maintenance (TPM), 5S, and Kanban. A mixed-method approach was adopted, combining quantitative indicators (MTTR, MTBF, OEE, service order response time, and inventory levels) with qualitative assessments of employee adherence and organizational practices. The implementation involved seven pillars: Routine Management, Operations, Results, Quality, Training and Development, Health and Safety (SSMA), and Maintenance. Key actions included task standardization, preventive and corrective maintenance planning via IBM Maximo, 5S-driven workspace organization, and visual Kanban systems for spare parts management. Results demonstrated reduced downtime, improved maintenance efficiency, higher asset availability, and enhanced process reliability. The integration of Lean tools fostered continuous improvement, employee engagement, and a culture of operational discipline. The study concludes that Lean Manufacturing significantly improves maintenance performance and overall operational excellence in an LPG filling plant.