Application of the DMAIC method integrated with neuroengineering principles to improve production layout aiming to increase productivity

Abstract

This research investigated the integrated application of DMAIC methodology and neuroengineering principles to improve the productive layout, inventory management, and execution of manufacturing activities in a metalworking industry that manufactures industrial kitchen equipment. In this sense, the objective of this research was to apply the DMAIC methodology aligned with neuroengineering principles to improve the layout and ensure more balanced and lean operations. The methodology used lean manufacturing resources such as spaghetti diagrams and the Kanban system to minimize waste related to excessive movement, inadequate layout, intermediate inventories, and production bottlenecks. Improvements were implemented in the physical arrangement, reorganization of the production flow, redesign of workstations, and implementation of pneumatic devices to improve the perception of less physical effort in production management. The results show a reduction of up to 59% in operational movements, an increase of up to 23% in productivity, and improved neuroergonomics perception with resized workstations. It is concluded that the integrated approach of the DMAIC method and neuroengineering principles with lean manufacturing resources in business management constitutes an effective and replicable model for small and medium-sized industrial companies, promoting simultaneous gains in operational performance and the perception of well-being of the workforce.