Avaliação do estado da arte da engenharia de produção na indústria naval brasileira: um estudo de caso no estaleiro Atlântico Sul

Abstract

This case study deals with the evaluation of the use of the best practices of Production Engineering in the naval industry, having as background the Estaleiro Atlântico Sul (EAS). It is a descriptive and explanatory case study. The project describes the evolutionary trajectory of the EAS Production System, characterizing it in three distinct phases. In Phase I, which begins in 2008 and extends until July 2014, it is identified a significant influence of the historical factors of the naval production in Brazil that had strong influence of the Taylorist / Fordist paradigm, and can be synthesized by the fact that the production of ships was perceived as a ' construction ' with the management of the several ‘disciplines’. Phase II, which occurred between July 2014 and January 2016, constituted a transition phase that had as its central element the goal of modifying the organizational culture of the company, which was accomplished through the adoption of concepts such as: 5S, mini factories and Kaizens focused on improving production flows and process-focused quality. And in Phase III, which begins in January 2016, has as a critical event the creation of a full-scale EAS model that aims to create a holistic view of the company and the production system. Phase III has as its theoretical basis the Toyota Production System and the Theory of Constraints (TOC), and an important conceptual modification was made regarding the perception of the 'work object' throughout the EAS production system. The changes that occurred under the aegis and focus on the Process Function were central to the creation and improvement of production flows throughout the production system. In order to sustain the changes that occurred in Phase III, there was a broad reformulation in the management model with the creation of the concept of Factories (Blocks, Painting and Edification) that started to have specific managers responsible for the incremental and radical improvements of the productive flows. In addition, actions were taken with respect to the Operation Function: i) implementation of the concept of Workstation Management in the restrictive cutting machines; ii) generate several production lines using the box concept, with a more general view of flow from the TOC Drum / Buffer / Rope perspective, with the intensive use of the Standard Operation concept for their design. Also, through a report from a Korean consultancy, it was possible to understand a set of gaps between the production system model currently adopted in the company under study and the Korean benchmarking. From this evolutionary historical perspective of the development of the EAS production system, the paper proposes the adoption of a series of good practices in order to improve the processes in the company under study. Finally, as a conclusion, it seems possible to affirm the adherence and applicability of the concepts of production engineering in the naval industry, and its application has a direct impact in terms of the company's economic and financial improvements