Daily production management based on Lean Manufacturing: strategies for process optimization and control in the logistics sector

This study investigates the application of Daily Management (DM) based on Lean Manufacturing principles in the logistics sector of an industrial unit in the oil and gas industry, referred to as Alfa Company. This sector was selected due to the opportunity to analyze key performance indicators (KPIs) more accurately, given the operational nature of logistics processes and the relevance of these indicators for measuring efficiency and equipment availability. The research addresses the following question: how does Daily Management influence employee engagement and operational effectiveness in Alfa Company’s logistics? The study aimed to understand the impact of DM on employee engagement and operational performance, as well as to identify the main barriers to its consolidation. A qualitative exploratory approach was adopted, including direct observation, document analysis, and semi-structured interviews with employees across different hierarchical levels. Data were analyzed using Braun and Clarke’s (2006) Thematic Analysis. Results indicate that DM significantly improved team communication, decision-making agility, and process standardization. Overall Equipment Efficiency Total (OEET) increased from 37% to 48%, though still limited due to equipment maintenance time, which decreased from 4,681 to 3,750 hours annually after DM implementation. The study confirms that Daily Management contributed to reducing losses, enhancing equipment availability, and reinforcing a Lean culture in the sector. As a practical contribution, guidelines are proposed to optimize the use of indicators, consolidate operational discipline, and strengthen Lean leadership in sustaining improvements. Limitations include the small number of interviewees and restricted quantitative data due to corporate confidentiality. Nonetheless, the findings underscore the strategic value of DM as a tool for continuous improvement and collective engagement.