Professor at the Porto School of Engineering (ISEP), Polytechnic of Porto, Portugal, and Visiting Professor at the Polytechnic Institute of Viana do Castelo, Viana do Castelo, Portugal. More than two decades of experience in the industrial sector, having started his career in 1998. Initially as a junior consultant, he then took on the role of Production and Quality Director in a multinational company. From 2004-2020 he worked extensively with industrial companies as a Senior Specialist Consultant on projects to improve safety, reduce waste and increase productivity. In 2006, he began teaching in higher education and since 2020 has been a full-time lecturer at the Porto School of Engineering (ISEP), Polytechnic of Porto. He has also been in the a visiting professor at Lusófona University in Porto and at ISAG - European Business School. Has published more than 120 articles (WoS + Scopus), edited several books, participated in European projects and has been invited as a keynote speaker.
EDUCATION
He holds a PhD in Industrial and Systems Engineering from the University of Minho (Portugal)
In 2015, he was awarded the title of Specialist in Quality Management by the Polytechnic Institute of Viana do Castelo (Portugal), after successfully passing the public exams, in recognition of his professional career as an industrial manager and consultant in quality management and continuous improvement, as well as his contributions to the field through research.
RESEARCH, TEACHING, or OTHER INTERESTS
Industrial and Manufacturing Engineering, Safety, Risk, Reliability and Quality, Management Science and Operations Research
138
Scopus Publications
Scopus Publications
Condition maintenance and prediction system in an injection molding machine: a case study Daniel Rebelo, Joaquim Moreira, José Torres Farinha, Susana Nicola, Alzira Mota, Hélio Castro, Luís Pinto Ferreira, João Bastos, José Carlos Sá, Paulo Ávila Journal of Quality in Maintenance Engineering, 2026 Purpose In an increasingly competitive market, equipment availability is a strategic variable for the competitiveness and success of companies. The objective of the research in this article is to present contributions to reduce unplanned production stoppages and optimise the operational efficiency of an injection moulding machine. This will be achieved by developing a systematic strategy to integrate predictive and condition-based maintenance systems with maintenance management software. Design/methodology/approach The model developed is based on the continuous monitoring of electrical signals and vibrations, with the processing of data collected in real time through a script developed in Python. This integrates the information into the maintenance management software, facilitating a quick and accurate response to component wear conditions. The methodology employed was action research, as it was a case study developed in a real context, with active participation in development and implementation, with the aim of continuous improvement. Findings In August, a substantial increase was observed in the primary indicators: The mean time between failures (MTBF) increased by 97.36%, the mean time to repair (MTTR) increased by 313.31%, and the downtime was reduced by 65.04%. In December, although the figures were more moderate, significant improvements were maintained: The MTBF increased by 20%, the MTTR increased by 84%, and the downtime was reduced by 79%. Originality/value The findings of the study indicated that the implementation of a structured approach for the acquisition and monitoring of electrical signals and vibration data was imperative to achieve substantial gains.
Lean, Green, and Sustainability 4.0—A Systematic Literature Review Diogo Marques Vilaça, Jose Carlos de Sá, Jiju Antony, Michael Sony, Olivia McDermott Business Strategy and the Environment, 2026 This purpose of the study is to conduct a systematic literature review and bibliometric analysis to explore the integration of Lean–Green–Sustainability (LGS) with Industry 4.0 technologies for holistic organizational development. Following PRISMA guidelines, the study critically examines the evolving research, identifying an increasing convergence of Lean and Green principles with Sustainability, though systematic investigations into LGS and LGS 4.0 remain limited. The study finds that the field is growing, with significant research emerging from India, Brazil, and the United States. A conceptual framework is developed to guide organizations in the successful implementation of LGS 4.0, emphasizing its role in enhancing operational efficiency, economic and environmental impact reduction, and social and governance sustainability. This study contributes by synthesizing the current state of LGS research and setting the agenda for future studies. It also provides practical insights for organizations seeking to integrate LGS 4.0 principles. As one of the first and most comprehensive studies on the synergistic and complementary nature of LG, LGS, and LGS 4.0, it offers valuable theoretical and managerial implications for sustainability‐driven digital transformation.
MAPIC - A NEW COMPREHENSIVE METHODOLOGY FOR PROCESS IMPROVEMENT Paulo Avila, Roberto Monteiro, Alzira Mota, Helio Castro, Luis Pinto Ferreira, Joao Bastos, Nuno O. Fernandes, Joaquim Moreira, Jose Sa International Journal for Quality Research, 2026 The use of process improvement methodologies to assist and support the improvement of processes has proven to be an important mechanism for effectively implementing these improvements.However, there is difficulty in choosing the best methodology and to ensure that it will lead to the best improvement results.In this sense, the research questions of this work can be formulated as the following: H1 -There are differences between the major process improvement methodologies and gaps not covered by them; H2 -A new process improving methodology may mitigate the gaps identified in the existing process improvement methodologies.Comparing the main process improvement methodologies available in the literature, namely, PDCA, Six Sigma, DMAIC, QC Story, 8D, TOC and Lean, it was proven the research question H1.To validate the research question H2 a new process improvement methodology, the MAPIC, was then proposed and compared with the other methodologies.From a theoretical view point, the research question H2 was validated, because the MAPIC covers the existed gaps from the others methodologies, namely, that there is no phase to promote proactive continuous improvement, nor to validate the proposed improvement before its implementation.As for its practical validation, the MAPIC is being applied in a case study and the results will be presented in further work.
A global industrial perspective on lean industry 4.0: a qualitative wide-angle lens approach Peter Hines, Guilherme Luz Tortorella, Jiju Antony, David Romero, Aidan Walsh, Darrin Taylor, Anabela Carvalho Alves, Massimo Bertolini, Rodrigo Caiado, Krisztina Demeterj, José Dinis-Carvalho, Luís Pinto Ferreira, Diego Fettermann, Moacir Godinho Filho, Paolo Gaiardelli, Graham Howe, Guven Gurkan Inan, Maneesh Kumar, Chi Hieu Le, Florian Magnani, Juan Manuel Maqueira, Josefa Mula, Michael Packianather, Paulo Peças, Maria Teresa Ribeiro Pereira, Daryl Powell, Anupama Prashar, Masood Ur Rehman, José Carlos Vieira De Sá, Henrik Saabye, Selim Erol, Leonor Teixeira, Helen Zak Production Planning and Control, 2026 This paper provides an insight into the global state of Lean Industry 4.0 (LI4) with over 1,000 industry responses. The approach employs a rigorous qualitative open-response survey. Our findings indicate that there was no unified industry perspective of LI4 terminology. The evolution of I4 is taking a similar path to Lean and making the same mistakes by not focusing on leadership, engagement, competencies, and behaviours. Past academic research has perhaps over-emphasised the environment and supply chain. The benefits of LI4 application are largely in terms of efficiency, cost reduction, learning and engagement. This work contributes by highlighting research avenues: why a piecemeal approach has been taken by industry to LI4, why LI4 has not been more widespread, and more detailed studies around contingent factors). It also provides industry with lessons on how to implement LI4 and the mistakes to avoid such as seeing implementation as a purely technical exercise.
Using the Lean-Based Safety Leadership Framework to Improve Operational Efficiency and Reduce Occupational Risk: Evidence from a Case Study Tiago Rodrigues, José Carlos Sá, Ana Rita Oliveira, Peter Hines, Robert Ulewicz, Andrei Bonamigo System Safety Human Technical Facility Environment, 2025 This study explores the integration of Lean methodologies with occupational safety enhancement in an industrial context. Conducted in a renown Rope factory, the research utilized an Action Research methodology guided by a novel Lean-Based Safety Leadership Framework. Through the implementation of Lean tools such as SMED, 5S, Poka-Yoke, and Visual Management, it is possibe to improve both operational efficiency and occupational safety. A Safety Efficiency Value Stream Mapping (SEVSM) approach was employed to diagnose risk points and inefficiencies within one of the factory’s sectors. The intervention led to a significant reduction in operational risk and improvements in productivity, validating the framework’s effectiveness as a dual-propose tool for safety and efficiency.
The role of leadership in teams and in business José Salvador da Motta Reis, Déborah Silva de Almeida Gastão, Nilson Rodrigues da Silva, Gilberto Santos, Luís César Ferreira Motta Barbosa, José Carlos de Sá Production Engineering Archives, 2025
Development of a Variant Process-Planning Tool: A Case Study Paulo Ávila, Bebiana Santos, Alzira Mota, Hélio Castro, Luís Pinto Ferreira, João Bastos, José Carlos Sá, Joaquim Moreira, António Duarte Santos, Gilberto Santos Quality Innovation Prosperity, 2025
Lean, Six Sigma and ISO Management Systems Standards: An Integration Framework International Conference on Quality Engineering and Management, 2024
Preface Lecture Notes in Mechanical Engineering, 2024
The Impact of SMED on Productivity and Safety José C. Sá, Rita C. M. Sales-Contini, Francisco J. G. Silva, José Dinis-Carvalho, L. Cardoso, Luis Fonseca IFIP Advances in Information and Communication Technology, 2024
The value of TPM for Portuguese companies Eduardo Vaz, José Carlos Vieira De Sá, Gilberto Santos, Florbela Correia, Paulo Ávila Journal of Quality in Maintenance Engineering, 2023
Implementation of Lean Six Sigma to Improve the Quality and Productivity in Textile Sector: A Case Study Genett Jiménez-Delgado, Iván Quintero-Ariza, Jeremy Romero-Gómez, Carlos Montero-Bula, Edgar Rojas-Castro, Gilberto Santos, José Carlos Sá, Luz Londoño-Lara, Hugo Hernández-Palma, Leonardo Campis-Freyle Lecture Notes in Computer Science Including Subseries Lecture Notes in Artificial Intelligence and Lecture Notes in Bioinformatics, 2023
The importance of subcontracting and its relationship with Lean philosophy inautomotive industry ISEP - School of Engineering, Polytechnic of Porto, Portugal, Sara Sá, Luís Pinto Ferreira, ISEP - School of Engineering, Polytechnic of Porto, Portugal;, Francesco Silva, ISEP - School of Engineering, Polytechnic of Porto, Portugal;, José Carlos Sá, INEGI—Instituto de Ciência e Inovação em Engenharia Mecânica e Engenharia Industrial, 4200-465 Porto, Portugal;, Maria Teresa Pereira, INEGI—Instituto de Ciência e Inovação em Engenharia Mecânica e Engenharia Industrial, 4200-465 Porto, Portugal;, Gilberto Santos, IPCA - Design School, Polytechnic Institute Cavado Ave, Barcelos, Portugal International Journal of Industrial Engineering and Management, 2022
The contribution of Obeya for business intelligence Gonçalo Sousa, José Carlos Sá, Gilberto Santos, Francisco J. G. Silva, Luís Pinto Ferreira Design Applications and Maintenance of Cyber Physical Systems, 2021
A Model for Productivity Improvement on Machining of Components for Stamping Dies ISEP - School of Engineering, Polytechnic of Porto, Porto, Portugal, João Carlos da Silva, Francisco José Gomes da Silva, ISEP - School of Engineering, Polytechnic of Porto, Porto, Portugal, Raul Duarte Salgueiral Gomes Campilho, ISEP - School of Engineering, Polytechnic of Porto, Porto, Portugal, José Carlos Vieira de Sá, IPVC - Instituto Politécnico de Viana do Castelo, Viana do Castelo, Portugal, Luís Carlos Ramos Nunes Pinto Ferreira, INEGI - Instituto de Ciência e Inovação em Engenharia Mecânica e Engenharia Industrial, Porto, Portugal; International Journal of Industrial Engineering and Management, 2021
Selecting the best tools and framework to evaluate equipment malfunctions and improve the OEE in the cork industry ISEP - School of Engineering, Polytechnic of Porto, Rua Dr. António Bernardino de Almeida, 431, 4200-072 Porto, Portugal, Paulo Marinho, Daniel Pimentel, ISEP - School of Engineering, Polytechnic of Porto, Rua Dr. António Bernardino de Almeida, 431, 4200-072 Porto, Portugal, Rafaela Casais, ISEP - School of Engineering, Polytechnic of Porto, Rua Dr. António Bernardino de Almeida, 431, 4200-072 Porto, Portugal, Francisco Silva, INEGI - Instituto de Ciência e Inovação em Engenharia Mecânica e Engenharia Industrial, Rua Dr. Roberto Frias, 400, 4200-465 Porto, Portugal, José Carlos Sá, INEGI - Instituto de Ciência e Inovação em Engenharia Mecânica e Engenharia Industrial, Rua Dr. Roberto Frias, 400, 4200-465 Porto, Portugal, Luís Pinto Ferreira, INEGI - Instituto de Ciência e Inovação em Engenharia Mecânica e Engenharia Industrial, Rua Dr. Roberto Frias, 400, 4200-465 Porto, Portugal International Journal of Industrial Engineering and Management, 2021
Lean Contribution to the Companies’ Sustainability Pedro Teixeira, José Carlos Sá, Francisco José Silva, Gilberto Santos, Pedro Fontoura, Arnaldo Coelho IFIP Advances in Information and Communication Technology, 2021
Lean manufacturing applied to the production and assembly lines of complex automotive parts Lean Manufacturing Implementation Opportunities and Challenges, 2019
Perception of the importance to implement ISO 9001 in organizations related to people linked to quality-an empirical study International Journal for Quality Research, 2019