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- Analysis and improvement in the Electrical Discharge Machining process used on the manufacturing of moulds for plastics injection mouldingPublication . Costa, A; Pinto Ferreira, Luís; Silva, F. J. G.; Sá, José Carlos; Pereira, Teresa; Ávila, PauloDue to increasing competitiveness in the industry, companies will invariably adopt strategies to ensure that their employees continuously eliminate waste and create more value. This concept was applied at a company that designs, develops, and manufactures steel moulds for the injection of thermoplastics, with the purpose of implementing Lean thinking in the production sector, thus achieving the following objectives: organization of production; preparation of documents to support production, and standardization of graphite stock. Regarding the application of the 5S tool, an improvement in worker safety, and in cleaning was observed, which also led to a reduction in the time wasted when locating tools. Through the implementation of 5S auditing, enabling to verify an overall improvement, from a rating of 35% in the first audit to 85% in the subsequent audit. The tools implemented allowed for improvements in communication between sectors, leading to increased productivity and productive autonomy. Finally, graphite stock was standardized by means of Kanban.
- Safety efficiency value stream mapping (SEVSM) - A new tool to support the implementation of Lean SafetyPublication . Marques, J P; Sá, José Carlos; Silva, F. J. G.; Pereira, Maria Teresa Ribeiro; Pinto Ferreira, Luís; Santos, GOccupational health and safety constitutes a topic of great importance in organizations nowadays, given the social and financial implications that arise. In addition to these problems, the manufacturing industry is greatly responsible for the number of accidents at work worldwide. In parallel, organizations focus on improving processes and eradicating waste from production flows. Therefore, there is a need to develop tools which are able to combine these two factors. Metalworking industry suffers of safety problems usually due to the great weight of the parts involved, as well as the processes used. The Safety Efficiency Value Stream Mapping (SEVSM) tool was developed to address these issues with the purpose of facilitating the identification of the risk level at each workstation, which is determined through risk assessment, as well as by verifying the type of risk which causes the security breach, and then indicating the most appropriate Lean tool to be applied for risk resolution. Besides these, it is also possible to obtain a diagnosis of the production flow, enabling an analysis of the most significant production indicators. The results obtained pointed to a 38% reduction in the risk level associated to job preparation activities through the introduction of Total Productive Maintenance, as well as a 31.8% reduction in compressor assembly process time, and 49.3% in the risk level related to the latter through Standard Work.