Mongo e automatização - tanta treta que se ouve

O meu parceiro das conversas oxigenadoras mandou-me este artigo, "Can There Be Too Much Automation?":

"Much of what you hear about automation focuses on the increased productivity that automation can bring to production lines. You hear about this a lot because it’s a true, measurable reality.
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But is it possible that too much reliance on automation can hinder the overall productivity of a factory? [Moi ici: Um velho tema deste blogue, Mongo e automatização não jogam bem!!! Ver Lista de artigos abaixo]
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At Mitsubishi Electric´s Kani manufacturing facility, which is part of the company’s Nagoya Works in Japan, the company found that, by bringing humans into work cells that were once 100 percent automated, the footprint occupied by the cell itself could be reduced by 84 percent.
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In addition, Mitsubishi Electric notes that the introduction of human workers to previously automated assembly lines is helping the Kani factory react faster to changes in product demand.[Moi ici: Tão Mongo!!!]
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The Kani factory produces motor starters and contactors for Mitsubishi Electric. The vast amount of production variations and possible configurations of these products—14,000—diluted the volumes of each particular product. This amount of variability, coupled with customer demands for even greater choice, highlighted the automation problem for Mitsubishi Electric. [Moi ici: Tão Mongo!!!]
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According to the company, manual production at the Kani factory had given way to totally automated assembly lines, which were ideal for mass production with few product variations where high yields could be realized at high speed. But this required many individual components to be held in stock and ready for the manufacturing process; otherwise, the lines would not be able to run for any appreciable length of time.
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In effect, it became difficult and uneconomical for the factory to produce its products in small batches—which just happens to be the very direction in which industry as whole is headed.
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The company realized that, by restoring some human elements, it could reduce some of the manufacturing problems it was encountering.
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Despite that fact that the new cells, featuring a combination of human workers and automation, cannot produce at the same volume and speed as the fully automated lines, the reduced size of the new cells means the company can deploy up to 6.3 cells in the same space once occupied by one cell. Mitsubishi Electric says this means that total productivity density for the facility is much higher due to three key factors: a wider variety of products can be manufactured in smaller batches; one stoppage does not halt the whole of production; and the total number of production lines has increased."

Como escrevo no postal de Fevereiro de 2018 na lista abaixo:

"Muitas vezes penso que as pessoas quando planeiam o futuro não fazem como Teseu no labirinto, não usam uma corda para unir o hoje com o futuro desejado. Por isso, usam lugares comuns. Por isso, não põem os pés no chão e testam a validade dos pressupostos que estão a assumir." 

1. Estranhistão, autenticidade, imperfeição e automatização (Agosto de 2013) 
2. Um mesmo processo automatizado é demasiado rígido para Mongo (Abril 2014)
3. Mongo e a automatização... pois! (Fevereiro 2016)
4. Beyond Lean (Agosto 2017)
5. Seru (parte V) (Setembro 2017)
6. Da normalização para a excepção (parte II) (Fevereiro de 2018)
7. Coisa de loucos (Maio de 2018)
8. O que protegerá Portugal dos robôs? (Outubro de 2018)
9. Nem de propósito! (Dezembro de 2018)

"O que passa-se?" (parte II)

Parte I.

O artigo continua com um exemplo já conhecido aqui do blogue, a Local Motors (postal de 2012, outro de 2016 e outro de 2017).

"A small U.S. startup called Local Motors offers an intriguing glimpse into the future of manufacturing. The company manages five so-called microfactories around the world, which primarily use 3D-printing equipment to produce such modern-day curios as Olli, a self-driving shuttle bus with IBM Watson artificial intelligence that can be hailed via a smartphone app and follows voice instructions; a cargo-carrying drone for Airbus dubbed the Zelator; and the world’s first 3D-printed car, the Strati — road-worthy if not a speedster — built live in 44 hours at the International Manufacturing Technology Show.
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But the 3D-printing aspect of Local Motors’ business model is just a small part of what makes this company worth examining. The company is also crowdsourcing production designs from a network of global participants,
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As the microfactory concept evolves, Local Motors will build new plants wherever its customers are located, and each manufactured item will effectively be one of a kind, built to suit the tastes and requirements of individual consumers. Scale is replaced by potential savings from engineering, design, parts, labor, and efficiency in a 3D microfactory. Local Motors describes this approach as making money from scope. In other words, it offers useful, attractive, bespoke products to customers who are within shouting distance of its factories, at a price that matches the distinctive value of the item.
Local Motors is still a nascent business — and may or may not ultimately succeed — but at its core it reflects a vital shift in production dogma that manufacturers of all sizes will have to reckon with in the coming years. After decades of chasing lower production costs and scale by extending factory footprints and supply chains deeper into emerging nations and distributing products around the world in huge quantities over complex logistics networks, manufacturers are finding that their globalized approach is losing its viability. In particular, their centralized management structure, lengthy supply chains, lack of product variety, and long shipping times are impeding regional agility — and, in some cases, placing them at a disadvantage to local competition.
Instead, the new strategic archetype for successful manufacturers will be based on a relatively simple idea: The most efficient manufacturing setup is the one that makes goods in appropriate volumes to meet demand at the point of demand, with plenty of room for local and individual customization. Much of this concept will be driven by advances in technology — 3D printing, factory innovations, e-commerce, data analytics, and the Internet of Things, to name a few
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Moreover, the impact of the point-of-demand model will not be limited to the business-to- consumer environment. Suppliers in the business-to-business realm will also be under pressure to improve responsiveness as part of the campaign by their customers — that is, manufacturers — to shorten the value chain and more proactively serve the end consumer.
The implications are problematic for some companies: Manufacturers that are today highly invested in a global factory network of multiple large centralized plants, managed by traditional operating systems, organizations, and processes, may find their business models becoming obsolete faster than they ever expected. [Moi ici: Recordar esta reflexão de 2014] However, the nimblest manufacturers stand to reap significant gains from this new model. As their supply systems become more responsive and as customer demand becomes less of a guessing game, inventory inefficiencies and the carrying costs of warehousing products in bulk — only to ultimately jettison some of them as dead stock — will decline. In addition, savings will be generated by the reduction in expensive long-range production planning and supply chain management. And for companies able to outpace rivals in producing products that are best suited to customer needs — making these items available when customers want them — sales margins should rise markedly."

Conseguem imaginar como isto vai mudar o paradigma económico? Conseguem visualizar o fim do mundo criado pelo século XX?

"O que passa-se?"

Normalmente aqui no blogue, chamo a atenção para a cegueira das empresas de consultoria grandes, parece que escondem dos seus clientes grandes o impacte de Mongo na sua actividade.

Julgo que é a primeira vez que encontro um texto de uma consultora grande sobre Mongo e as suas implicações na economia, nos ecossistemas e na dimensão das empresas.

"In the next manufacturing revolution, spurred on by technologies that reinvent the way a factory can create products, such as 3D printing and robotics, companies will also need to rethink what they make and where they make it. Products will come off the assembly line in small, highly customized batches, like a high-tech version of old-fashioned craftsmanship. [Moi ici: Digam lá se isto não é uma entrada à matador com Mongo em toda a linha!!! Desde os pequenos lotes até aos artesãos tecnológicos longe das máquinas-monumento tão queridas dos que pensam que o Normalistão do século XX automatizado será o paradigma produtivo do século XXI]
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The revolution is on its way, and within the next five to 10 years, manufacturers in all industries will find themselves in a race to efficiently produce products at the point of demand — that is, where their customers are — and to deliver these items when their customers want them, personalized to their customers’ individual tastes. They will have to make strategic choices to stay competitive, investing in technology that allows them to continually analyze data about their customers’ preferences and buying habits so they can adapt quickly to changes in market conditions. Factories will be smaller, [Moi ici: Imaginem os cromos da Junqueira ao ler estas blasfémias!] operating with minimal lead times and shorter value chains. Management will be decentralized, the supply chain will be simplified and shortened, and the distance separating the manufacturer from its customers will be sharply reduced.
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Although technology will enable this new manufacturing model, customers will compel its adoption. In emerging markets as well as developed regions, customers increasingly expect products that match local cultural preference rather than homogeneous global brands and business-to-business services. The auto industry pioneered this localized model as long ago as the 1980s, when Japanese automakers entered the U.S. market with cars tailored to American tastes. But only recently have other industries taken up this approach — with refrigerators, toothpaste, furniture, clothing, and software that are designed for each region. The popularity of e-commerce has changed the customer experience, giving people more information about products and competitors’ products, pricing, and, through peer reviews, quality. For the first time, customers can reasonably demand from mass producers products that look and feel like they were made next door.
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Nimble manufacturers will reap significant gains from the point-ofdemand model. As their supply systems become more responsive and as local customer demand becomes less of a guessing game, inventory inefficiencies and the carrying costs of having to warehouse products in bulk will decline. The expense of supply chain management and production planning will drop as well. And companies able to produce personalized products that are best suited to customer needs when customers want them will enjoy higher sales margins. By contrast, as point-of-demand manufacturing takes hold, companies that operate global factory networks with large centralized plants, managed by traditional operating systems, organizations, and processes, may find that their business models are outmoded."

Ao chegar aqui recordei, "Pedro Nuno Santos quer Estado como motor do desenvolvimento", porque estava a nascer em mim um outro pensamento, o oposto... o que esperar de um contrarian-militante! O que seria a orientação geral de um governo para facilitar a transição para este tipo de sociedade?

Empresas pequenas, DIY, empreendedorismo verdadeiro não treta para sacar Portugal 2020, fiscalidade normanda, legislação laboral, democratização da produção.

Esta transição vai acontecer, inevitavelmente, pedida, ordenada pelos clientes, pelas tribos de Mongo. E teremos governos cada vez mais incapazes de perceber o que se passa, questionando-se, "O que passa-se?", cada vez mais crentes nas virtudes do Normalistão, num mundo que se afasta cada vez mais desse paradigma.

Trechos retirados de "Manufacturing’s new world order: The rise of the point-of-demand model"

E as pessoas para a Indústria 4.0?

Recordar as diferenças entre "Calçado italiano e português".

Qual tem sido a evolução do calçado português?

Qual tem sido a evolução demográfica?

Qual tem sido a evolução da disponibilidade de pessoas para trabalhar?

Qual tem sido a evolução do emprego no sector?

• Patrão da indústria do calçado diz que faltam 2.000 trabalhadores no setor
• Calçado criou quase dez mil novos postos de trabalho

Relacionar com "Benvindo ao futuro (parte II)" e com o facto de continuarmos a embrenharmos-nos em Mongo onde todos somos únicos e orgulhosos disso.

O meu parceiro das conversas oxigenadas há muito que me chamou a atenção para o facto de toda a gente falar na Industria 4.0 (sem acento, está em estrangeiro) e ninguém falar das pessoas da Indústria 4.0

Sábado recebi este convite que aceitei de imediato:

Na minha mente isto está tudo relacionado, basta recordar o que escrevo sobre a automação e a sua incapacidade de lidar com as séries de Mongo, o que descobri sobre o seru.

Da normalização para a excepção (parte II)

Parte I.

Muitas vezes penso que as pessoas quando planeiam o futuro não fazem como Teseu no labirinto, não usam uma corda para unir o hoje com o futuro desejado. Por isso, usam lugares comuns. Por isso, não põem os pés no chão e testam a validade dos pressupostos que estão a assumir.

Acerca da variedade de Mongo e da sua conjugação com a automatização já escrevi, por exemplo:

• Estranhistão, autenticidade, imperfeição e automatização (Agosto 2013)
• Um mesmo processo automatizado é demasiado rígido para Mongo (Abril 2014)
• Mongo e a automatização... pois! (Fevereiro 2016)
• Beyond Lean (Agosto 2017)

Agora encontro:

"From fearing exceptions to celebrating exceptions. In the scalable efficiency model, where process efficiency is the source of performance improvement, exceptions and deviation from the norm are typically seen as a problem that is either slowing us down or creating costly waste. For those measured on the efficiency of a process, dealing with exceptions can be an unwelcome distraction from executing the standard process. For the individual, the department, and the organization, all of the incentives and systems encourage minimizing variances and even hiding those that occur. Meanwhile, the potential opportunities—to serve the customer in new ways, to use new tools or create new value— go unexplored. This is where the opportunities to improve an organization’s performance may arise.
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As the number of exceptions increase for frontline workers, organizations should embrace and celebrate exceptions as an opportunity to improve performance. At the very moment when much of business, government, and society is consumed by the idea of machines taking our jobs and what that will mean for humans, we risk letting what differentiates us from machines atrophy. Humans are better at handling exceptions than machines are."

Trecho retirado de "Beyond process - How to get better, faster as “exceptions” become the rule"

Da normalização para a excepção

Primeiro, recordo este postal "Redsigma - O fim da linha" de Agosto de 2013:

"O advento de Mongo obriga a mudar de paradigma. Há meses que ando a namorar com o inevitável... o nome Redsigma está esgotado!!! Redsigma foi uma marca que criei em 1991 ou 92. Reduzir o sigma, reduzir a variabilidade, apostar na standardização. Lentamente, comecei a mudar e hoje, sou quase um inimigo declarado da normalização... prefiro apoiar empresas a estarem à frente da onda, tão à frente que ainda não existem normas. Prefiro apostar na variedade do que estar preocupado com a variabilidade.)" 

Depois, volto a "Beyond process - How to get better, faster as “exceptions” become the rule": 

"What is likely to ramp up performance for the organization? Accelerating performance uses different levers than have been used in the quest for scalable efficiency. Organizations that want to pursue this opportunity will need to focus their attention differently than where most are today.
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Focus on exception handling as a catalyst for performance improvement. [Moi ici: Sempre que se está numa empresa de calçado este é um tema recorrente, o excesso de amostras, a quantidade de pequenas séries, a saudade pelo tempo das grandes séries e das cores uncial - preto e castanho] One consequence of the relentless, rapid changes of the Big Shift [Moi ici: A Deloitte usa este termo, assim como eu uso o termo Mongo] is that many employees in large companies [Moi ici: Pobres gigantes. Por isso, o sucesso das Font Salem e das Lusomedicamenta] are already spending more of their time on “exceptions”—those unexpected issues that fall outside the realm of ex- isting standardized processes. These exceptions can be early signals of changing customer needs or shifting contexts that represent potential threats or significant new opportunities for growth for the company. Embedded in them is the opportunity to develop new approaches and new solutions to deliver more value in response to some new need or circumstance. Organizations that focus on improving their ability to handle exceptions—not just to resolve or eliminate them but to glean learning and create value from them—will discover a valuable source of performance improvement, especially if exceptions increase. Variances and deviations from the norm are the bane of efficiency but can fuel learning and new ways to improve performance over time.
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Focus on value creation as the key driver of performance. While costs can’t be cut any lower than zero, the potential for value creation has no such bounds. [Moi ici: Como não recuar a 2008 e à originação de valor] Focusing on new value creation can be the key to getting on a trajectory of accelerating performance improvement."

No Verão passado descobri o Seru e fiquei surpreendido por ninguém falar dele. Ainda há muito a aprender, quanto tempo será preciso para fazer esta transição da normalização para a excepção?

Como o mundo muda ...

Como o mundo muda ...


O Financial Times para ilustrar o artigo "Eurozone manufacturing sector growth hits record" recorre a esta imagem:

Uma linha de montagem de bicicletas na Europa.

Por acaso fica-me a dúvida, será que uma linha de montagem é a solução mais adequada para a produção de bicicletas na Europa no século XXI?

Talvez na Roménia ou em Portugal, mas julgo que a marca da figura é holandesa e talvez o Seru fosse mais adequado.

Cuidado com as melhores práticas

"Similarly, when Michelin, the tyremaker, tried to introduce lean production methods — as pioneered by Toyota — in the 1990s, it succeeded in improving productivity at the expense of agility and at a cost to its carefully nurtured humane corporate culture."

E o que é que Mongo requer? Agilidade e mais agilidade.

BTW, sublinho de "Customer experience investment fails to pay off as performance hits all-time low":

"“Businesses are still organised in the same way they were in Victorian times when we were building factories that churned out consistent objects. We’re now in a world where we sell concepts, content, ideas and thoughts [Moi ici: Em linha com "the more important it is to think about boundaries"] and the traditional organisational structure really isn’t effective in being able to do that.”"

Cuidado com as melhores-práticas, cuidado com o benchmarking e com o uso que se dá à caneta.

BTW, aquela perda de agilidade da Michelin fez-me recordar as 8 semanas de congelamento:

"These practices are combined with the tradition within Toyota Production System of freezing the production schedule eight weeks before production begins, which substantially reduces responsiveness."

Trecho inicial retirado de "Best practice can make lemmings of us all"

"short-lived consumer trends"

“If you’re selling the same merchandise that’s commonly available, and you’ve got no point of differentiation, you’re dead,” Mr. Rubin said. “It’s just a question of when you die.”

Comecei a perceber como materializar isto com um artigo na revista Business Week em 2005 sobre o fim das linhas de montagem da Canon. E com a leitura em 2006 do livro "How We Compete: What Companies Around the World Are Doing to Make" onde encontrei trechos como este sobre a Kenwood:

"When Kenwood moved production of portable mini-disk players from a factory in Malaysia to their Yamagata, Japan, plant in 2003, they discovered they could exploit short-lived consumer trends."

Em 2017, esta abordagem continua a ser notícia, no país dos gringos:

"When Alejandro Villanueva, a Pittsburgh Steelers offensive lineman, stood for the anthem and the rest of the team stayed in the locker room, his name began trending on Twitter. Fanatics quickly posted a rendering of his No. 78 jersey on its website and on the N.F.L.’s online shop, which it also operates.
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Sales skyrocketed. Manufacturing facilities in Kentucky and Florida went to work pressing Mr. Villanueva’s name and number onto thousands of blank Pittsburgh jerseys for next-day shipping. Overnight, a player who had never caught a pass or scored a touchdown had the N.F.L.’s best-selling jersey.
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“That moment happened, people wanted to immediately buy that jersey,” Michael Rubin, the company’s chairman and principal owner said. “A week later, that moment is mostly over.”
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These micro-moments, as Mr. Rubin calls them, happen all the time in sports: A player reaches a milestone, has a breakout performance or is traded to a new team. Apparel companies have traditionally been poorly positioned to meet the accompanying fan demand as it surges. Fanatics is changing that and, in the process, carving out a lucrative niche in a fiercely competitive online-retail industry largely dominated by Amazon."

Trechos retirados de "Fanatics, Maker of Sports Apparel, Thrives by Seizing the Moment"

Futurizar

""A crescente automatização de processos gera necessidades de pesados investimentos em processos produtivos que, para serem rentabilizados, exigem taxas de ocupação elevadas, no limite tendendo para a laboração contínua."

Mas Mongo não vai nesta direcção, Mongo é diversidade, flexibilidade, rapidez, irregularidade.

De um lado um exército clássico do outro uma célula da Al-Qaeda.

Mais tarde ou mais cedo as limitações do modelo (que impõem estas restrições de quantidade) vão gerar oportunidades para organizações tipo-Local Motors e quiçá, se os governos não continuarem prisioneiros das corporações, a uma réplica do que aconteceu com a explosão da cerveja artesanal.

Trecho retirado de "Fabricantes advertem que sucesso do setor automóvel depende de ganhos de produtividade"

BTW, a seu tempo veremos pedidos de apoio para os contribuintes, via Estado, apoiarem estas empresas a montarem represas para atrasar a sua inevitável derrocada/reformulação porque os seus clientes terão desaparecido e as Local Motors preferirão fornecedores mais pequenos.

Seru (parte V)

Parte I, parte II, parte III e parte IV

"Seru Seisan, also called “beyond lean” in many Japanese manufacturing industries, is an innovation of the production management mode in Japan. Although an increasing number of manufacturing enterprises in Japan have been adopting this strategy with great success, it is not popular among manufacturing enterprises and researchers out of Japan.
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Mass production, symbolized by the conveyor line, is a kind of universal production management mode that has been widely adopted by numerous manufacturing enterprises all over the world. The long history and popularity of the conveyor line influenced peoples’ minds. Implementing the conveyor line in manufacturing industries, especially in final assembly processes, became a constant thinking pattern. Hence, people could not imagine that a high performance production management mode was rising in Japan and gradually taking the place of the conveyor line in some manufacturing fields.
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Over the past decade, several Japanese manufacturing enterprises have dismantled their conveyor lines and adopted Seru Seisan.
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Seru Seisan is an innovation of the production management mode in Japan. It emerged from a very complicated environment of mixed factors both in and out of Japan. The main factors are as follows.
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Change of demand to high variety and low volume [Moi ici: Aquilo que caracteriza Mongo]
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Demand changes are embodied in two main aspects: product variety and product volume. From the standpoint of product variety, the diversified and personalized demand leads to high product variety. The shortened product life cycle also results in diversified products. Moreover, fluctuations in customer demand have negative effects on product volume.
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The efficiency of the conveyor line will dramatically decrease when confronted with variable and fluctuating demands. Therefore, highly efficient but less flexible conveyor lines should be urgently replaced by manufacturing organizations pursuing high flexibility. In Japan, Seru Seisan is currently regarded as the most powerful approach in some manufacturing industries to deal with the dynamic environment with high product variety and low product volume.
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Low flexibility of the conveyor line.
The conveyor line is popular in the final assembly processes of mass production systems due to its high efficiency. Its other advantages include high productivity, superior product quality, low product cost owing to economy of scale, and low labor cost by low-skilled workers. ... The major demerit of the conveyor line centers on its lack of flexibility. Almost every conveyor line is designed for one or several specific product types. Therefore, measures should be taken to reconstruct the line when the product type changes. Meanwhile, it is essential to adjust the line in order to obtain high performance against the fluctuating demand volume.
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Long period of economic stagnation in Japan after 1991.
The expansion of automation was curbed in the 1990s because manufacturing enterprises could not afford the additional enormous amount of capital investment required for automation during the economic recession. Moreover, managers gradually realized that high-cost automation could not always bring the sound effect as expected because of unstable customer demand. Therefore, the requirement for low-cost but highly efficient systems arose reasonably under the influence of an external economic factor and an internal performance factor.
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The economic stagnation of the 1990s prompted Japanese manufacturing enterprises to dismantle their highly efficient conveyor lines and begin to innovate on their production management mode."

Trechos retirados de "Seru Seisan- An Innovation of the Production Management Mode in Japan" publicado por Asian Journal of Technology Innovation 18, 2 (2010)

Acerca de Mongo

"When Voodoo launched, Friefeld said that the team began to realize that they were serving two different markets. The first market is made up of engineering companies that are launching new products and which need to produce a few thousand products for early testing and validation.Voodoo works with these firms to produce the first few thousand enclosures and other parts for their designs. The second market consists of marketing materials and other aesthetic products.
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How can a 3D printing company compete with the $162 billion injection molding market? Voodoo accomplished this by purchasing off-the-shelf 3D printers, which require very little up-front investment when compared to an industrial manufacturing operation. Running a series of print farms, Friefeld said that his startup is cost-competitive with injection molding for runs of up to 10,000 units. For print runs above that, it usually makes more economic sense to have parts made with injection molding.
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“With Voodoo, there’s no up-front investment,” Friefeld said.“We can get started with the file and get your part the next day, or 10,000 parts in two weeks. We’re fast and we have very little startup costs with our process.That’s all because we’re using 3D printers—digital manufacturing tools that can take in a digital file and produce a physical product with little human interaction. No tool, no tooling, no jigs, no fixtures. File in, product out.”
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“Ultimately, we will be producing low-volume runs of any manufactured product anywhere in the world,” Friefeld said.“[We’re] starting with plastic today, but we’ll eventually expand into other materials and processes built on top of these digital tools like 3D printers.”"

Isto encaixa perfeitamente na narrativa acerca da caminhada para esse novo mundo económico que designo por Mongo. Um mundo de diversidade e com cada vez menos necessidade de grandes séries.

Há algum tempo discutia-se numa empresa a necessidade de investir numa unidade toda automatizada, ao estilo 4.0, para se especializar na produção de grandes séries. Sinto que os escandalizei quando os tentei convencer a fazerem o contrário: investir numa nova unidade pequena, mas para se concentrar nas pequenas séries.

As empresas grandes pensam nas séries grandes e não dão a atenção suficiente às pequenas séries e a um outro estilo de marketing, de actividade comercial e de produção que requerem. Pensem no Director Comercial de uma empresa grande. Pensem no desafio que ele tem de enfrentar todos os anos de aumentar as vendas para ir ao encontro de objectivos de facturação muito ambiciosos. Pensem como o volume de vendas é muito mais fácil de medir que o lucro unitário obtido com essas mesmas vendas. Pensem como esse Director terá tendência a matar/asfixiar todos os projectos de novos produtos e serviços que não prometam pelo menos X de vendas rapidamente. Julgo que a única hipótese que uma empresa grande tem de fazer a transição para Mongo, é a de criar spinoffs e colocar gente apaixonada  e obrigada a passar fome de recursos, à frente desses projectos. (Interessante como esta referência a gente apaixonada me fez recordar este podcast recente de Nassim Taleb, "Nassim Nicholas Taleb on Work, Slavery, the Minority Rule, and Skin in the Game")


Trechos retirados de "Voodoo Automates 3D Printing to Take on Injection Molding"

Artesãos do futuro

Ao folhear muitos postais deste blogue é fácil relacionar entre si algumas palavras-chave:

• Mongo;
• tribos;
• diferenciação;
• paixão;
• artesãos;
• autenticidade.

Por exemplo, há dias escrevi:

"Em paralelo a esta evolução, que vai sugar os mais apaixonados para uma nova Idade de Ouro de artesãos do século XXI"

No caderno de Economia deste fim de semana encontrei um texto que relaciona estas mesmas palavras-chave, "À procura de artesãos no tempo dos ecrãs táteis":

"No entanto, quem aposta com visão em segmentos como o têxtil, a carpintaria, a latoaria, a joalharia, a encadernação, a cerâmica, os bordados, o restauro ou a cestaria pode ter um futuro promissor pela frente,
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outra área de forte procura: o trabalho artesanal em madeira. “Todos os dias chegam pedidos de marceneiros, profissionais de serralharia artística.” São cada vez mais, também, os casos de sucesso de novos negócios, sempre de nicho, que começam no risco, chegam à autossustentabilidade e culminam na exportação.
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Ao contrário do preconceito que possa persistir, de que o trabalho do artesão é pesado, sujo e moroso e de que a produção não se adaptou ao consumidor contemporâneo, “o artesanato não ficou estagnado”, sublinha Luís Rocha. O sector está a rejuvenescer e a qualificar-se.
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a formação superior conjugada com a técnica adquirida nos cursos profissionais resulta na evolução criativa que tem dinamizado o sector. Ao mesmo tempo, “a procura [de produções artesanais] tem aumentado porque o mercado está cansado do produto massificado e quer, cada vez mais, objetos com forte cariz cultural, identitários e diferenciadores”. Cabe ao artesão “ganhar essa oportunidade”, analisa o diretor, que defende o investimento em marcas culturais com design de luxo.
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Se nos domínios da carpintaria, marcenaria e costura, encontrar emprego por contra de outrem é relativamente comum, nos nichos da cerâmica artística, vidro ou bordados, muitos não esperam que o mercado chame por eles e criam diretamente oportunidades, uma situação que se terá acentuado nos últimos seis anos. “O desemprego fomentou o empreendedorismo e isso foi muito importante para dinamizar o sector”"

E na linha do que tenho reflectido aqui sobre o seru e a não-necessidade de máquinas-monumento , sobre o impacte de Mongo na dimensão das empresas, sobre o impacte da digitalização na redução da fricção de que falava Coase, na ascensão do DIY e dos makers, é interessante a referência aos ecrãs tácteis no título. Acredito que os artesãos do futuro trabalharão cada vez com mais tecnologia e mais valor acrescentado.



BTW, ontem fui a Rio Tinto com 4 moradas de lojas e fábricas de candeeiros. Ao chegar a uma delas, com todo o aspecto de oficina artesanal, deparei-me com caixas com marcas de renome e referências a feiras italianas. Fui recebido com atenção e simpatia mas comunicaram-me que tinham deixado de trabalhar para o público e começado a trabalhar para marcas portuguesas do segmento médio-alto e focadas na exportação.

Decisões de localização (parte II)

Parte I.

Na leitura final de "From Global to Local" de Finbarr Livesey encontrei uma série de trechos sobre decisões de localização com os quais concordo embora com algumas dúvidas:

[Moi ici: Primeiro algo sobre Mongo] "While new production technologies are not going to give us Star Trek like 'replicator' any time soon, they are enabling smaller factories to be  economically viable. They do this by lowering what is referred  to as minimum economic scale, the lowest volume of production for which the investment in the factory is financially viable. [Moi ici: Isto é Mongo a 100%. A democratização da produção]
.
The simple view of production was that bigger is better: you offset large capital costs by having a factory that produces in high volume with extreme efficiency. The case for ever increasing sizes of factory hits barriers of coordination if the factories become too large and the level required to be efficient or cost competitive has fallen as additive manufacturing and other techniques have developed and improved their performance. [Moi ici: BTW, a seu tempo os políticos descobrirão isto mas só depois de provocar muito sofrimento com as escolas-cidade, os hospitais-cidade, os tribunais-cidade, as esquadras-cidade, ...] A key implication of techniques like additive manufacturing is that they remove the need for specialised components such as moulds or forms to be made specific to the product working its way down the assembly line. [Moi ici: Pesquisar a palavra japonesa "seru"] As well as saving cost and time by not having to make these specialised pieces, it also means that a factory can more easily make a variety of products. Rather than thinking of the investment in a factory being tied to one product, the costs can be offset against the income generated from a series of products, hence a lower minimum economic scale for each product. With lower scale, the likelihood of having a greater number of smaller factories instead of a small number of extremely large factories goes up. And as that happens the factories are going to be geographically dispersed, lowering the number of trade movements necessary to get a product to customers in different countries.
...
[Moi ici: Agora sobre decisões de localização] The second level of change is a strengthening of the regionalisation of trade. The temptation is to work at the extremes — everything is global or everything is local. This misses the subtleties that are needed in industrial organisation and the diversity that exists in manufacturing. Regionalisation will be driven by the balance of forces between the scale required to have efficiencies and the desire to reduce time to customer and the costs of being in different countries simultaneously.[Moi ici: Sinto que há muito de verdade neste último trecho. Unidades produtivas muito eficientes a trabalhar para todo o mundo produzindo artigos fáceis de transportar e pouco dependentes da vontade do cliente na sua versão final. Unidades produtivas ágeis e mais pequenas, talvez a trabalhar para mercados até 3/4 dias de camião, mais próximas do lugar de consumo, permitindo produções com séries curtas, reposições rápidas, alterações de design e iterações rápidas. Unidades produtivas junto do consumo para permitir customização, interacção, co-criação ]
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It is worth noting that even though the declining importance of distance for trade has been accepted as a stylised fact for many years. distance has always moderated trade. [Moi ici: Ghemawat tem um livro com uns gráficos espectaculares que ilustram esta realidade] The further away from one another two countries are, the smaller the level of trade we would expect to see between them. A recent review of over one hundred academic papers on the effect of distance on trade indicates that the average effect means that to per cent increase in distance lowers bilateral trade by about 9 per cent? Distance continues to matter even with absolute transport costs falling and increasing digital interconnection around the world. [Moi ici: Depois disto tudo tenho dúvidas num aspecto. Se a digitalização e a conectividade reduzem as fronteiras, como conciliar tudo isto com a técnica alemã de procurar clientes-alvo independentemente da geografia? Acredito que a diferenciação que trabalha para nichos e que não se baseia na interacção mas antes na vantagem tecnológica ou de design crescerá baseada na conectividade digital sem olhar à geografia]
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With smaller factories being economically viable and tooling costs falling due to increased use of techniques like additive manufacturing, companies can produce for the different regions of the world independently rather than attempting to have a global product. [Moi ici: Teremos pois, é fácil de prever para os próximos anos, a criação de unidades produtivas de multinacionais para servirem continentes e não o mundo]
...
In a regionalised scenario a company may not have its supply chain and final assembly all in the country in which it will be selling its products. They can organise themselves and their suppliers across the region. However, in some cases that won't be the best way to be organised, for example if time is really an issue. If there cannot be a lag of, say, a week to get goods from Mexico to the east coast of the USA, then the company will need to have at least final assembly in the country of purchase, if not more of the supply chain feeding that assembly process for your product.
...
At the third level within regions we are likely to see agglomeration or clustering effects. These clusters arise as there are positive effects for companies to be close to other companies im similar sectors.
...
As we move into a world where products have shorter journeys to get to us, where factories are smaller and there are more of them, and where is great uncertainty about what work we will be doing, the other elements of globalization will also continue to evolve. Nothing in the trends we have described will by themselves reduce or block digital globalization."

Beyond Lean

Há anos que escrevo aqui sobre o advento de Mongo e o consequente impacte na dança entre produção e consumo:

• mais tribos;
• mais nichos;
• séries mais pequenas;
• mais flexibilidade;
• mais rapidez; 
• mais variedade;
• mais diferenciação;

Em paralelo há anos que se lê com cada vez mais frequência sobre a automatização da produção.

Em Mongo, a produção é muito diferente da do paradigma do século XX com séries longas e planeamento da produção feito com muita antecedência. Em Mongo o planeamento da produção é feito cada vez mais em cima e é mais volátil. Como é que a automatização e as organizações-cidade lidam com Mongo?

"With improvements in living standards and a transformation in people’s ideas of consumption, much of the current electronics manufacturing industry is confronted with market demands characterized by variety and volume fluctuation. Manufacturing system flexibility is useful to address such fluctuated market demands.
...
Seru production has been called beyond lean in Japan and can be considered to be an ideal manufacturing mode to realize mass customization
...
seru production relies on low-cost automation and has little automation. When reconfiguring a conveyor assembly line into serus, expensive large automated equipment is substituted with simple-structure equipment with similar functions. The reconstructed equipment can be easily duplicated and modified at a low cost, so as to avoid equipment-sharing conflicts among multiple serus and reduce investment in equipment.
...
Factories that produce multiple electronics product types in small-lot batches tend to adopt seru production. Compared to mass production, which displays its superiority in the case of a narrow range of product types with high product volumes, seru production would be affected by low efficiency and high cost in such an environment.
...
Using highly automated production systems, mass production factories can attain high production efficiency. However, they usually achieve low production flexibility. As both the variety and volume fluctuations of market demands increase, mass production factories may need to reconfigure their traditional conveyor assembly lines for their survival and development.
...
Seru production is human-centered manufacturing. Multiskilled operators are important resources to implement seru production, more important than in mass production. The equipment used in seru production is simple and not automated. The effect and influence of equipment on the performance of seru production systems is less than that on mass production systems. Accordingly, a practical production planning system for seru production should consider multiskilled operators more than equipment. In a dynamically changing manufacturing environment, a dynamic production planning system is needed"

Anónimo da província mas muito à frente:

• Um mesmo processo automatizado é demasiado rígido para Mongo
• Mongo e a automatização... pois!
• "mas o essencial é que o mercado de massas desapareceu"

Cuidado com os media, desconfie sempre!

Trechos retirados de "An implementation framework for seru production" publicado por Intl. Trans. in Op. Res. 00 (2013) 1–19

Outro festival de blasfémias

Continuado daqui.

Agarre-se às cadeiras, segue-se mais um festival de blasfémias:

"The alternate to costly multipurpose or special-order machines is inexpensive, slower, and fewer-purpose machines, but many of them. Every work cell that needs one gets one and can then function autonomously. Although a multipurpose machine offers high flexibility through quick changeover and rapid production rate, all else equal, conventional fewer-purpose machines might provide even greater flexibility when employed in a number of manufacturing cells. Conventional machines are also simpler to operate and less costly to maintain.”[Moi ici: Pode estar aqui uma oportunidade para os fabricantes portugueses de máquinas?]
Constraining that three-pronged potential, however, is the tendency of manufacturers to retain SP practices in spite of their limited responsiveness. Such dysfunctional decision making ... tends to be chosen for local efficiency rather than effectiveness - remains in force today.
Several authors emphasize the importance of avoiding monument equipment consider the potentially negative impact on responsiveness of smoothing the production schedule as commonly
...
concurrent production relies on multiple, relatively slow-paced, simple, small-footprint, low-cost productive units, sometimes referred to as right-sized
...
As the number of production units increases, so does the degree to which production becomes concurrent with demand; and as the degree to which equipment units are dedicated increases, so does concurrency.
...
“Abolish the Setup,” points to the liabilities of “a single, expensive machine that can produce many kinds of parts,” compared with several less-expensive, dedicated machines.
Small, inexpensive units of capacity can be readily reconfigured, which grows in importance as customer preferences proliferate.
...
CP builds factory infrastructures around multiple product-family or customer-family-focused units - cells, machines, production lines, plants-in-a-plant - with simple, compact, low- cost, “right-sized” equipment and avoidance of monument-sized equipment. The primary objectives of CP are to reduce customer lead times and distribution inventories. Longer-range benefits to the organization as a whole include better customer retention, market penetration, and sales growth. In an era when customers increasingly demand higher variety from manufacturers, CP is timely, making it possible to reap the benefits of responsiveness while keeping production costs low enough for competitiveness."

Trechos retirados de "Missing link in competitive manufacturing research and practice: Customer-responsive concurrent production" publicado por Journal of Operations Management 49-51 (2017) 83-87

Seru (parte IV)

Parte I, parte II e parte III.

"seru highlights the need to define productivity more specifically in terms of value creation, rather than output. Elaborating the definition of produc- tivity and the TSEF in this way provides insight into why and how production operations deploying seru have been competitive in spite of high labor and other costs."

Posso ser um anónimo da província mas ando muito, muito à frente. Perdoem-me a falta de modéstia.

Seru (parte III)

Parte I e parte II.

"The typical seru implementation process can be summarized as follows:
1. As customer demands fluctuate, assembly line inefficiencies become apparent and a strategic choice to emphasize responsiveness is made.
2. Assembly lines are dismantled and replaced with divisional seru systems through resource collocation and removal/replacement, cross-training, and autonomy.
3. Expensive dedicated equipment is replaced by inexpensive general-purpose equipment that can be duplicated and redeployed as needed by serus.
4. As cross-training progresses, divisional serus evolve into rotating serus and yatais.
5. As the seru system matures, cell configurability is developed so that exactly the cells required to meet demand can be rapidly formed, then dismantled once demand is met.
...
In the years leading up to 1992, production of most high- volume, low-value-added Japanese products was being shifted to low-cost countries because of the Japanese yen's sharp rise. Sony's products did not lend themselves to such offshoring, however, because they were characterized by high variety, low volume, and high value added, with frequent design updates and generational changes. Sony first attempted to respond to its high demand volatility by applying the Toyota Production System mixed-product method to its conveyor lines, but the demand volatility for Sony products substantially exceeded that of Toyota. Rapid changes in product technologies and configurations called for lines to be reconfigurable, whereas the Toyota Production System emphasized investments in expensive, synchronized, integrated production lines. Thus, Sony chose to design its production system to respond to demand volatility, rather than eliminate it as occurs under the Toyota Production System.
...
Conveyers were replaced by workbenches, and simple equipment and manual tools were used, so that serus could be constructed, modified, dismantled, and reconstructed quickly and frequently. Although divisional serus were considerably more flexible than assembly lines with respect to product variation and volume changes, the demand for some products was volatile enough to require even more flexibility, so some of the divisional serus were converted into rotating serus.
...
As product variants proliferate and product life-cycles shorten, needs for changeovers and transitions rise. In this case, assembly lines with highly specialized workers and equipment (and resulting costly and lengthy change- overs) are likely to struggle more and more to maintain acceptable levels of utilization (uptime). Given the need to meet these highly varying demands, seru systems actually produce swifter and more even flows than assembly lines, because they handle transitions more quickly and efficiently. The emphasis under seru that all tasks are completed in a single cell, all required resources are made available in the cell, and that everything not required is eliminated, has as its objective to support the swift and even flow of products."

Trechos retirados de "Lessons from seru production on manufacturing competitively in a high cost environment" publicado pelo Journal of Operations Management, 49-51 (2017) 67-76.

Continua.

Seru (parte II)

Parte I.

"we define a lean operations strategy as one that prioritizes minimization of use of resources through reducing variability and minimizing buffers, and a responsive operations strategy as one that prioritizes the ability to respond to demand volatility (product and quantity), which then requires buffering either with capacity or inventory.
...
Seru is a type of cellular manufacturing (CM).
...
When demand is highly volatile, however, the value of smoothing demand tends to be lower than the value of responsiveness. Similarly, streamlining the operation of an assembly line through use of the takt time is possible when what is produced does not change, but a rapidly changing product mix eliminates such productivity gains. These practices are combined with the tradition within Toyota Production System of freezing the production schedule eight weeks before production begins, which substantially reduces responsiveness. Assembly lines organized according to Toyota Production System practices can be highly efficient when demand volatility is low. As demand volatility increases, however, assembly lines lack the needed responsiveness and lose the stability that is the source of their outstanding efficiency. Seru thus begins with the transformation of assembly lines into cells. Seru cells resemble biological cellular organisms in that they can be easily constructed, modified, dismantled, and reconstructed, hence the name seru, a Japanese word for cellular organism. In contrast to the fixed cells described elsewhere in the literature, seru cells are defined by their configurability, which plays a key role in their responsiveness. These assembly cells - designed to permit orders to flow seamlessly through the factory - represent a choice to prioritize responsiveness over efficiency.
...
[Moi ici: O trecho que se segue é tremendo, quando eu falo de Mongo e muita gente fala de automação. Recordar: "Não acredito nestas relações simplistas" e "In principle, the production of virtually any component or assembly operation could be robotized and moved to high-wage countries—but only so long as demand is great enough, and design specifications stable enough, to justify huge scale and hundreds of millions, if not billions, in upfront investments."] When production is organized into a single assembly line, the cost of large-scale automation may be justified by efficiency gains. When demand volatility is high enough to warrant cellular manufacturing, large and costly automated equipment needs to be replaced by small, flexible, and relatively inexpensive equipment that can be duplicated as needed."

Trechos retirados de "Lessons from seru production on manufacturing competitively in a high cost environment" publicado pelo Journal of Operations Management, 49-51 (2017) 67-76.

Continua.

Seru (parte I)

Em 2005 na revista Business Week encontrei um trecho que nunca mais esqueci e que citei neste postal de 2006, "Deixar de ser uma Arca de Noé":

"Canon is also looking to boost productivity. Already, the company has seen great gains from "cell assembly," where small teams build products from start to finish rather than each worker repeatedly performing a single task on a long assembly line. Canon now has no assembly lines; it ditched the last of its 20 kilometers of conveyor belts in 2002, when a line making ink-jet printers in Thailand was shut down."

Em 2010 no postal "Para quem se queixa da China... (parte IV)" escrevi:

""In the 21st century industry, all successful strategies rely on speed-to-market. Speed-to-market, in turn, can operate only where there exists trust, cooperation and collaboration between customer and supplier. To achieve this, we must change the very nature of our industry strategies." (Moi ici: e as fábricas conseguem guarnecer-se de talento para falarem como parceiros com as marcas e não como recebedoras de encomendas? E os fabricantes de máquinas conseguem agarrar a oportunidade de desenhar as máquinas que permitirão trabalhar com estas séries e frequências? E o lean aqui não será de muito uso, estamos a falar de uma nova organização da produção..."

Agora, passados estes anos todos:

"The past three decades have witnessed waves of offshoring by manufacturers in developed countries pursuing low-cost sources of production. Companies like Canon and Sony provide exceptions to the popular offshoring trend. Recognizing that their markets required responsiveness that extended supply chains could not provide, these companies pioneered a production system known as seru that has made it possible to manufacture competitively and profitably in Japan.
...
Producing locally has then strengthened their capacity to innovate. In ensuing years, hundreds of Japanese companies, especially electronics makers, have adopted seru, touting impressive benefits. The seru experience provides a useful lens for understanding how manufacturing can be competitive in a high-cost economy.
The seru production system is a type of cellular manufacturing that is distinguished first by the cells being configurable rather than fixed; and second by its use of cells for assembly, packaging, and testing rather than fabrication alone. Seru is defined by its prioritization of responsiveness over cost reduction in setting the firm's operations strategy.
...
Seru was developed to cope with high demand volatility and short product life cycles. Innovative manufacturing firms face the challenge of being flexible enough to handle significant process and environment variabilities, yet efficient enough to produce at a competitive cost. A considerable literature suggests that efficient production is best achieved through lean manufacturing, which typically seeks to reduce buffers and to eliminate demand volatility.
...
Interestingly, seru was explicitly developed as an alternative to the Toyota Production System (the precursor to lean). The developer of the seru concept - an expert in the Toyota Production System - concluded that implementing the Toyota Production System would not be appropriate in an innovative industry where the primary objective is to respond to demand volatility and fast product development cycles. Rather than adding agility to leanness ... seru begins with the objective of responsiveness: Seru's originators sought to achieve a smooth flow of a wide variety of products and volumes while using resources frugally."

Trechos retirados de "Lessons from seru production on manufacturing competitively in a high cost environment" publicado pelo Journal of Operations Management, 49-51 (2017) 67-76.

Continua.