ISEP – DEM – Livro, parte de livro, ou capítulo de livro
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- Lean manufacturing applied to the production and assembly lines of complex automotive partsPublication . Rosa, Conceição; Silva, Francisco; Pinto Ferreira, Luís; Sá, J. C.The automotive industry currently generates a great impact on world economy, presenting itself as a sector which is completely globalized, subject to constant development, and at the forefront of technology. It is one of the most important industrial activities worldwide, thus playing a fundamental role in the economy of the most industrialized countries, and already occupies a relevant position in developing economies. It is the true “industry of all industries” (Rosa et al. 2018, 555-556) (Costa, Silva, and Campilho 2017, 4043-4044).
- Lean manufacturing applied to a complex electronic assembly linePublication . Silva, F. J. G.; Baptista, Andresa; Pinto, Gustavo Filipe; Correia, DamásioManual assembly lines are usually deeply studied before implementation. Nevertheless, several problems upsurge when the product needs to be slightly changed. This is very common in complex electric and electronic devices usually produced in small batches, where the customers are demanding more and more features and the product needs to be continuously updated. However, these updates sometimes create huge difficulties for the previously installed assembly line, generating as well, line unbalancing and wastes of time regarding the initial situation. In this chapter, a deep study of an adjusted assembly line of electronic devices was carried out using Value Stream Mapping (VSM) method to fully understand and document the different tasks and operations. The Lean Line Balancing (LLB) was also applied in order to reduce the line bottleneck by balancing the line, becoming the Cycle Time (CT) lower than Takt Time (TT) in each workstation and the workers are not overburdened with their task. Standardized processes and standardized work were also applied. During the line layout development stage, assembly fixtures, wastes reductions and visual management techniques were applied as well, different concepts were generated and proposed and, finally, the best solutions were selected. Throughout the study, many benefits for the studied manual assembly line were found, which can be considered as a strong motivation to apply Lean Manufacturing (LM) tools for better line efficiency and production rate. The implementation of Lean methodologies endorsed an increase in the productivity of approximately 10% maintaining the same workforce, only modifying workstations and work methodologies. This chapter describes the importance of Lean manufacturing concept in modern industries.
- Quality and safety continuous improvement through lean toolsPublication . Santos, Gilberto; Sá, José Carlos; Oliveira, J.; Ramos, Delfina; Ferreira, C.The purpose of this chapter is to suggest the use of several lean tools that can be used, indicating the improvements that can be obtained with each of the recommended tools. The main objective is to be a contribution to the organizations, showing how they can detect the wastes in the productive flow through VSM, and at the same time to improve the quality of products through lean tools. The method presented was a case study. The various lean tools were also collected and described. This chapter intends to show several lean tools that can be applied in different situations, as well as, the wastes that each can eliminate and the benefits that are obtained from each one. Throughout the production process, with the support of Value Stream Mapping (VSM), it was possible to detect several wastes. A case study is presented as results from a work carried out in a company that is dedicated to the production of mechanical equipment. This work can be a guide to support organizations that wish to start their lean road. Smart value creation remains today dependent on the maturity of how lean management tools are applied. Lean, innovative technologies, critical knowledge, talent and big data need other dimensions to be sustainable. Quality and safety continuous improvement through lean tools, as well as, Industry 4.0 assumes a critical pillar for the new journey toward the future of our organizations.
- LEAN and ergonomics: how to increase the productivity improving the wellbeing of the workers – a case studyPublication . Santos, J.; Silva, F. J. G.; Pinto, Gustavo Filipe; Baptista, AndresaThe principles of Lean manufacturing, in addition to addressing the reduction of waste throughout manufacturing processes, are also highly concerned about the conditions that can favor the productivity of operators, which is achieved through their well-being while performing tasks. This work was elaborated with a view to the analysis of a production line capable of producing different electronic devices and which presented deficiencies in terms of operator ergonomics, demanding undesired and exhausting efforts, having as aim the elimination of such conditions. Thus, a detailed study of the movements carried out by the operators along the assembly line was elaborated, and possible solutions were considered to eliminate the situations that were perceived as more tiring and capable of generating health problems for the operators, when repeated several times. The study was successfully developed, and solutions were found that completely eliminated actions that required exaggerated efforts or unnecessary movements, clearly optimizing the assembly flow and the well-being of the operators in the line.
- The eighth waste: non-utilized talentPublication . Brito, Marlene; Ramos, A. L.; Carneiro, P.; Gonçalves, Maria AntóniaIn a changing economic climate, characterized by great pressure to improve productivity and reduce costs, industries use different management approaches, with lean manufacturing being the most popular in recent years. Lean manufacturing is based on value creation for the customer and the elimination of the waste which occurs during the production process, while improving working conditions. There are eight types of waste in lean manufacturing. The well-known seven wastes are production process-oriented, while the eighth waste is directly related to management’s ability to utilize personnel. This type of manufacturing waste occurs when management in a manufacturing environment fails to ensure that all the employees’ potential talent is being well utilized. This talent refers to management’s ability to use critical thinking and continuous improvement feedback from employees to improve a lean manufacturing process. When management does not engage with manufacturing employees on topics of continuous improvement and allow employees to produce change for the better, that is considered a manufacturing waste. Although performance management and the use of the employees’ talent are crucial to ensure a competitive advantage, there is a lack of research regarding this type of waste: non-utilized talent. On the other hand, there is a lot of literature addressing process-oriented wastes. The purpose of this work is to explore this “talent waste” and identify the contributing factors for this type of waste, such as: lack of reward, lack of recognition, lack of motivation, lack of training/knowledge, organizational injustice, undefined goals, etc. A tool is also introduced which takes the form of a questionnaire that will allow managers to evaluate their workers and help them to identify if there is “talent waste” in their companies, as well as the main causes related to this type of waste. To the authors’ knowledge this work is innovative and valuable because it will help companies increase employees’ performance, which is very important for organization sustainability.
- SMED applied to composed cork stoppersPublication . Sousa, Eduardo; Silva, Francisco; Pimentel, Carina M. O.; Pinto Ferreira, LuísA growing focus among organizations is their flexibility in production. The market pressure for products with large variety in small batches leads organizations to maximize their resources in order to be able to adapt their processes to constant changes. One of the most known barriers in processes flexibility is the equipment changeover time. To reduce this time and thus increase the processes flexibility and the organization competitiveness in the market, the Lean methodology can be applied, being Single Minute of Exchange of Die (SMED) methodology the most used Lean tool in this context. This chapter intends to present a practical case with mixed Lean tools application, being mainly focused on SMED study and implementation in cork industry equipment, leading to reduce the changeover time. There are several publications about SMED application in the most varied industrial areas, being this work an innovation in the cork industry. The equipment under study performs the connection between cork stoppers to capsules, which is done by glueing them with hot-melt glue. In order to start this kind of studies, it is important to know the initial equipment condition and for this the equipment data need to be initially collected. With these data, it is possible to identify the improvement opportunities. In order to recognize which activities really add value to the product, the Value Stream Mapping (VSM) technique is usually used. The SMED is applied as a mean to reduce the downtime caused by changeover activities. To follow the development of the SMED project, another valuable lean tool is the A3 report. Lastly, in a way to improve the monitoring of possible deviations during production, the Overall Equipment Efficiency (OEE) KPI can be implemented as an overall equipment efficiency indicator. The aforementioned lean tools were successfully applied in the composed cork stopper manufacturing process, resulting in a 43% changeover time decrease from 66:56 min to 37:59 min through the application of SMED and, at the end of this study it is possible to prove that lean tools and principles are a powerful approach to get solid profits without large investments, as well as their important contribution to increase the processes flexibility.
- Lean Manufacturing: Implementation, Opportunities and ChallengesPublication . Silva, Francisco; Pinto Ferreira, LuísThe paradigm of manufacturing is undergoing a major evolution throughout the world. The use of computers, the Internet and new challenges related to the Industry 4.0 have changed the way we engineer and manufacture products. Improving production with Lean Thinking is an evolution of a traditional approach in order to improve its processes to remain competitive in the global market. Lean Manufacturing is a multidimensional approach that embraces a wide variety of management practices in a unified system. These practices contain, quality systems, team work, and supplier management, among others. Nowadays, other practices have been adopted such as human factors and ergonomics. This book presents contributions of Lean Manufacturing applications in the world development and is intended to provide a comprehensive view of issues related to this area, with a specific focus on lean engineering principles; it is full of practical production examples of how Lean Thinking can be applied effectively to production systems. This work was conceptualized for an audience of graduate students mainly; however, it can also be consulted by engineers and company managers who seek state-of-the-art applications on Lean Manufacturing within a wide diversity of scenarios and conditions. The book, organized into 17 chapters, is intended to be an excellent source for dissemination of applied researches, lean concepts, and practices that have been successfully applied in the developing world domain. The book is also an excellent example of academy purpose with collaboration between different institutions from different countries that provide a global approach.
- Mechanical strength of thermoplastics and composite thermoplastics welded by laser – a reviewPublication . Pereira, A. B.; Fernandes, F. A. O.; Silva, Francisco José Gomes daThermoplastic welding is currently well implemented in the market, with several competitive and suitable processes, ranging from simple hot plate to ultrasonic welding. By its side, laser welding of plastics is still in a relatively early stage of research. This process is one of the most recent in the welding of thermoplastics and of great interest in the market. The welding technique is based on heating the thermoplastics by transmitting heat in the form of radiation. This is due to the ability of certain plastics to absorb the beam. Usually, one of the parts to be welded must be transparent and the other opaque to radiation. These two parts are kept under pressure as the laser beams are transmitted through the transparent part. The laser beam is concentrated in the joint area of the opaque part, heating and melting it. There are relatively few scientific studies on the joining of thermoplastics by laser and, in the case of thermoplastic matrix composites, there are even fewer. The main conclusion is that the mechanical strength of a laser welded joint is in the range of 30-50 MPa, a value that is frankly weak when compared to the value that the base material can handle and which is usually more than double for thermoplastics and 10 times for composites. Although the fusion process is contactless, one of the great limitations of laser welding of plastics is the need to exert pressure on the joint, which conditions and complicates the execution of a weld. However, despite everything, it is certain that laser welding presents mechanical strength values superior to those of a bonded connection and the processing time is much shorter, therefore, it is clear the interest on the process.
- Recent developments on friction stir welding of aluminium alloys: a comprehensive reviewPublication . Silva, Francisco José Gomes da; Pereira, A. B.; Fecheira, J. S.; Sousa, V. F. C.Friction stir welding is a relatively new joining technology, that has been succefuly applied in the connection of large and complex structures, with considerable progress being made throughout time. The development of this new solid-state welding technique has opened up new possibilities for joining similar and dissimilar materials, allowing the obtention of extremely interesting mechanical properties. This welding technique becomes even more interesting when applied to materials that are traditionally considered difficult to weld by conventional fusion methods. As it is well known, despite the fact that aluminum alloys have a low melting point, these are difficult to weld due, mainly, to their high thermal conductivity, requiring relatively high amounts of energy, wich can interfere with the low melting temperature of the alloys. Thus, numerous studies have been carried out around the Friction Stir Welding (FSW) process in various different alloys, however, given the intensive use of aluminum alloys in the most diverse sectors, these have deserved special attention by the researchers. In this chapter, the welding of different aluminum alloys with different process parameters and their influence on mechanical property of the joints are analyzed. This review intends to describe, in a structured way, the most recent developments around FSW of aluminium alloys, with special attention given to the microstructure and mechanical properties of the joints obtained by this process, as well as the parameters able to achieve the best joint properties.
- Cleaner Production: Toward a Better FuturePublication . Silva, Francisco; Gouveia, Ronny MiguelThis book provides an overview of cleaner production, including how regulations have evolved, and presents a broad perspective on how it is being developed. Presenting several practical examples and applications of modern clean production technologies, it provides readers with ideas on how to extend these practices to other industry sectors in order to contribute to a better environment in the future. The authors start from the initial concepts of how to implement new cleaner production systems, before collecting recent developments in the area and demonstrating practical ways in which the latest knowledge can be applied. It motivates readers to develop new ideas on how to improve manufacturing systems to save energy and generate less waste, and discusses strategies on how to save, reuse and adapt materials, as well as techniques to reduce the waste and pollution produced. This book serves as a reference resource for industrial management engineers and researchers, and is also of interest to undergraduate and postgraduate students looking for insights into cleaner production in industry.
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