Application of Project-Based Learning and Lean tools in a machining area of a welding industry

This paper has the objective of applying Project-Based Learning to propose improvements and measure the movement times in the machining area, using the Value Stream Mapping and Spaghetti Diagram as tools. This was a study developed by Graduation Students in Production Engineering of the Fluminense Federal University in partnership with a welding industry. The methodology can be classified as exploratory and descriptive, applying the bibliographic method to understand concepts related to machining, lean manufacturing, Value Stream Mapping (VSM) and Spaghetti Diagram, and it is also a case study, using the machining area of a welding industry as an analysis unit. The practices of project management recommended by the PMBOK Guide from Project Management Institute (PMI) were used, as well as the Project-Based Learning (PBL) methodology to drive the study in terms of research and application in the analysis unit. The activities of the machining area were mapped through the Value Stream Mapping and Spaghetti Diagram in order to identify the non-productive movements and time. Considering the results from the bibliographic search and the process mapping, alterations were proposed in the layout and order of activities and also, removed the ones that do not add value to the product. The improvements suggested to the welding industry were implemented and resulted in a reduction of 33h, equivalent to around EUR 5.000.