Lean production increases productivity and is the starting point of Industry 4.0

With the Industry 4.0 concept widening its path, companies have sought not only to improve their production with new technologies, but also to adopt methodologies that make processes more efficient, with better management and waste reduction, increasing, as a consequence. , your productivity.

For this, lean production programs are being put in place in companies. According to a survey by the National Confederation of Industry, 34% of the 2,338 manufacturing industries heard use 10 to 15 lean manufacturing tools. Another 39% use four to nine techniques and 27% apply up to three of the top 15 lean manufacturing techniques. Of these, 8% do not use any of the tools and 19% apply one to three techniques. Of the total number, 913 are small, 883 are medium and 542 are large.

Among the main lean manufacturing techniques, also known as the Toyota Production System, are the 5s, Kaizen, Kanban and TPM (Total Productive Maintenance) Program. According to the survey, the automotive vehicles, computer equipment and metallurgy sectors are the ones that most apply these tools.

Volvo, for example, has its own lean maintenance system based on the concepts of TPM and Lean Manufacturing, the VPS - Volvo Production System, spread at its Latin American headquarters, located in Curitiba (PR), where it follows the macro processes. with subprocesses adapted to local particularities. They are a series of methodologies and procedures that attack and eliminate waste in the production process, establishing a culture for continuous improvement of processes and people.

The principle for the implementation of processes such as these, an organizational culture based on the change of posture and mentality coming from the boss and collaborator, is the key point to reach the pillars proposed by the programs.

The tool called TPM assists in obtaining indicators, preventing equipment breakdown, increasing time between failures and reducing repair time, increasing the reliability and availability of equipment for production, and making the operator more identifiable with the equipment. process and with your machine. Basically, you avoid errors such as time consuming, constant and unorganized corrective maintenance and high rate of defective products due to process failures.

Lean manufacturing is crucial for the industries of this new era to be able to stay within a market that increasingly has the real gain in process optimization. Maximizing business efficiency and productivity is always the goal of every business owner. For this, it is essential that there is a production line without failures or unexpected stops. Achieving this reduces costs, reduces customer complaints, and increases net productivity. The main goal is to arrive at "zero break", "zero defect" and "zero crash" within the manufacturing process.

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