Uso de Ferramentas de Lean Manufacturing para Identificar os Fatores Geradores de Impactos Ambientais Associados a Desperdícios de Produtividade na Fabricação de Uniformes - Um Estudo de Caso em uma Indústria de Confecção de Uniformes no Polo Industrial de Manaus

Abstract

This article presents a study that demonstrates the applicability of Lean Manufacturing tools in identifying environmental impact factors in a clothing industry located in the municipality of Manaus, Amazonas. The focus of the study was on the company's production cells, specifically Cell 1, in the manufacturing of pants and PPEs. The results of the first part of the study revealed that a detailed analysis of the production flow through Value Stream Mapping (VSM) allowed for the identification of non-value-added processes that contributed to waste and environmental impacts, such as improper use of plotting papers, fabric waste in the cutting sector, and electricity usage in the sewing sector. The second part of the study highlighted the challenges encountered in the company's production process, including unplanned downtime, unbalanced operations, and interruptions for the insertion of different products on the same production line. The application of Lean tools such as Takt Time, TRF, Continuous Flow, Heijunka, and Standardized Work was identified as crucial in improving operational efficiency and reducing waste, thereby contributing to the minimization of environmental impacts. The overall results of the study showed that the application of Lean Manufacturing tools allowed for the identification of processes associated with invisible environmental impact factors, resulting in a significant reduction in waste indicators, especially in delivery, intermediate stocks, and rework rates. Additionally, there was a noticeable decrease in energy usage and textile waste disposal, generating a positive environmental impact. The study also presented a framework of conditional indicators and goals, revealing significant progress towards more efficient and sustainable production, with an overall reduction of 45% in waste indicators and established goals of at least 20% reduction in each indicator related to environmental impacts. This study demonstrates the effectiveness of Lean Manufacturing approaches in promoting more sustainable practices in the clothing industry.