Lean Thinking, Logistic and Ergonomics: Synergetic Triad to Prepare Shop Floor Work Systems to Face Pandemic Situations

Health crisis caused by COVID-19 had a significant impact on the activities and performance of companies worldwide, namely in industries. In this context, the adaptation of companies to the markets and to the new demands of consumers, readapt to strategies, processes, products, and approaches to the market, become paramount. In the case of companies, some changes in the shop floor work systems become essential, to provide competitive advantages in post-pandemic business scenarios, developing new approaches to increase the efficiency, agility and resilience of operations, always tends to account the Lean Thinking approach and its principles. Thus, the purpose of this article is to show that through Lean philosophy, Lean Logistics and ergonomic tools, one can change the manufacturing space and reduce human interaction in a post-pandemic scenario. In addition, through these three approaches associated with Industry 4.0, this article shows a project in a real case study in an automotive company, to integrate Automated Guided Vehicles (AGV) among other technologies. The study of AGV integration used a simulation model designed in Simio. This project could allow to significantly reduce the ergonomic risks, energy consumption and associated CO2 emissions, and the flow of materials within the organization. The costs could be reduced by 14% in the first year of implementing AGVs and 40% in the second year after implementation. Introducing autonomous AGV will reduce the need of interaction among employees which is fundamental for healthy environments in pandemic context.