Análise de processo em uma indústria de eletrônicos: um estudo de caso aplicando a metodologia A3.

Abstract

This study addresses the application of the A3 methodology, associated with the PDCA cycle and Lean Manufacturing principles at the manual assembly line of an electronics industry located in the Manaus Industrial Hub (PIM). The main objective was to analyze and demonstrate the impacts of implementing continuous improvement practices on production performance, operational efficiency, and workstation ergonomics. An applied, exploratory-descriptive research was conducted through a real case study. The method was based on direct observations, time studies, and the use of quality tools such as motion diagrams, the 5 Whys, and 5W2H to identify waste and propose countermeasures aimed at eliminating the root causes of the problems observed. The initial analysis revealed that inadequate workstation layout and lack of operational standardization resulted in inefficient material flow, excessive movement, and high downtime rates. After the implementation of improvements, the cycle time was reduced from 89 to 50 seconds, representing a 43.8% increase in productivity, along with layout optimization and ergonomic adequacy of workstations. The Act phase consolidated the standardization of the new practices through the update of technical documents and operator training, ensuring the durability of the results achieved. The findings confirm the effectiveness of integrating the A3 method with lean thinking as tools for continuous improvement, emphasizing their contribution to interdepartmental communication and organizational learning. It is concluded that the structured application of these methodologies is fully feasible in manual assembly environments and provides significant performance gains without requiring substantial investments, reinforcing the importance of continuous improvement culture and scientific process management.