Análise da capacidade produtiva de um fornecedor de peças metálicas de um novo modelo de motocicleta: um estudo de caso em uma indústria de duas rodas do polo industrial de Manaus.

Abstract

This study analyzes the challenges faced by Supplier X, responsible for producing metal components for a motorcycle manufacturer located in the Industrial Hub of Manaus, in meeting demand during the launch of new models. The main objective was to propose improvement actions for the supplier’s capacity planning, ensuring alignment between its production and the manufacturer's requirements. The research is characterized as a case study with a quantitative approach, using historical production data, technical reports, and operational measurements collected between 2022 and 2024. The critical stamping and welding stages of Component Z—an essential structural part of the motorcycle chassis—were evaluated. The results revealed that the production bottleneck lies in the welding process, with a cycle time of 260 seconds per unit, exceeding the required takt time of 236 seconds, in addition to inefficiencies such as unplanned downtime and rework. A comparative analysis between installed capacity and actual demand showed that welding operates near saturation, while stamping has significant idle capacity. It is concluded that the late capacity assessment (conducted only at PP3) limits the implementation of corrective measures, suggesting that this analysis be anticipated to three months before the start of production. It is recommended to optimize the welding cycle time through layout revision, preventive maintenance, and operator training, as well as to rebalance production between stages. This study contributes to supply chain management in dynamic environments, highlighting the importance of aligning production capacity with demand fluctuations in new product development projects.