Método de projeto de layout integrado à produção mais limpa (P+L): uma estratégia de implementação aplicada em pequenos negócios do setor moveleiro

Abstract

This thesis defends the development of the Layout design method integrated with Cleaner Production (CP) as a strategy to implemented CP, and focussed on small businesses in the furniture sector. To this end, it identified, analysed and developed parameters for integrating layout design methods and CP implementation; applied and evaluated the method in small businesses in the furniture sector; and analysed the minimisation of production losses related to natural resources and process waste in the case studies (CS1 and CS2). This is an applied qualitative and quantitative exploratory study. It was developed in four stages categorised as Inspiration (1), Ideation (2), Implementation (3) and Intervention (4); in 4 phases, theoretical foundation (A), development (B), application (C) and evaluation (D). Phase A included data collection, organisation and analysis. Phase B identified (i) parameters and points of convergence between layout design factors and criteria for implementing CP, (ii) the conceptual development of the method and (iii) formal prototyping. Part of phase C was CS1 in a furniture industry in Palhoça (SC); the other application was CS2 carried out in Maceió (AL) to evaluate the method, phase D. In CS1, waste in areas and flows was mapped and minimised, the area for stocks, for material in process and the supply flow lines were improved and reduced by 25.59%, 72.69% and 46.24% respectively, with a positive impact on production area, which was increased by 33.33%. The areas for disposing of materials were eliminated and those destined for by-products for internal/external reuse/recycling were reduced by 51.69% with the integrated allocation of collectors and shelves in the production centers, and creation of flows for by-products, an innovative link. In CS2, the production of a wardrobe was monitored and analysed before the project and implementation, and losses of 7,425 m2 of MDF were found due to mistakes in the cutting plans and lack of visibility of the stock in the plant, and 2,365 m2 of MDF discarded in landfill. The implementation of the LCP project improved environmental positioning, management space, training and functions, technical and technological aspects. The circulation area increased by 35.06% with improvements in the plant's production capacity, in the system efficiency of the production flows by 19.88% and in supply flows by 50.99%. There was a minimisation of production losses with natural resources and process waste, implementation of selective collection, reuse/recycling, and a 32.03% reduction in by-product flows, which are now detailed in a technical notebook; MDF leftovers are now separated, catalogued and organised in the plant for internal reuse/recycling, and scraps are destined for the Ecoponto and external reuse/recycling. The data from CS2 confirms that the LCP project is a strategy for implementing preventive socio-environmental thinking, promoting and enhancing the minimising production losses with natural resources, avoiding waste in processes at the source, guaranteeing safety and innovation in the workplace.