The dynamism and competitiveness in the various industrial segments have encouraged companies to develop ways of making their operations and production processes increasingly efficient, seeking alternatives to reduce the costs of their processes, increase the quality of their products, and become increasingly flexible to satisfy the needs of their customers. The purpose of Production Planning, Scheduling, and Control is to guarantee the quality of products, delivery as stipulated, lower costs, and efficiency of production processes; the Lean philosophy (lean manufacturing) comes to the rescue to help companies be more competitive because with the principle of identifying where the customer sees value in the product or service and mapping the entire value chain to look for waste to be reduced or, preferably, eliminated. The article aims to present a review of the concepts of Production Planning, Scheduling, and Control (PPCP) and Lean manufacturing and propose a structured procedure for integrating the Lean philosophy into production planning, scheduling, and control. The methodology developed is based on Value Stream Mapping (VSM) with a case study applied to a company in the food industry. Among the most relevant results were cost reductions by optimizing bottlenecks, minimizing intermediate stocks, and optimizing the production process. The contribution of this work is a detailed description of VSM in the planning, scheduling, and control of production in a food company.

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Integration of the Lean Philosophy with Production Planning, Scheduling and Control

  • Darcleia Forlin,
  • Marcelo M. Tibes Peluso,
  • Edson Pinheiro de Lima,
  • Sergio E. Gouvea da Costa

摘要

The dynamism and competitiveness in the various industrial segments have encouraged companies to develop ways of making their operations and production processes increasingly efficient, seeking alternatives to reduce the costs of their processes, increase the quality of their products, and become increasingly flexible to satisfy the needs of their customers. The purpose of Production Planning, Scheduling, and Control is to guarantee the quality of products, delivery as stipulated, lower costs, and efficiency of production processes; the Lean philosophy (lean manufacturing) comes to the rescue to help companies be more competitive because with the principle of identifying where the customer sees value in the product or service and mapping the entire value chain to look for waste to be reduced or, preferably, eliminated. The article aims to present a review of the concepts of Production Planning, Scheduling, and Control (PPCP) and Lean manufacturing and propose a structured procedure for integrating the Lean philosophy into production planning, scheduling, and control. The methodology developed is based on Value Stream Mapping (VSM) with a case study applied to a company in the food industry. Among the most relevant results were cost reductions by optimizing bottlenecks, minimizing intermediate stocks, and optimizing the production process. The contribution of this work is a detailed description of VSM in the planning, scheduling, and control of production in a food company.