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, et al. 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.
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, et al. 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, et al. Production Engineering Archives, 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, et al. 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
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, et al. 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, et al. 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, et al. 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