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- Optimization of the cold profiling process through SMEDPublication . Vieira, T.; Sá, José Carlos; Lopes, M.P.; Santos, G.; Félix, M.J.; Ferreira, Luís Pinto; Silva, F.J.G.; Teresa Pereira, MariaIn a more and more competitive and industrialized market, it is essential that companies realize that the way forward must go through the optimization of their production processes, reducing the costs and increasing product quality. Nowadays it’s necessary to adopt innovative management models that can provide increased productivity at minimal costs, such as the Lean thinking. The metalworking industry is integrated into one of the most competitive existing markets in Portugal. Given this, it’s fundamental to reduce the waste in all sectors of the production process, using the good Lean principles and practices, such as the Single Minute Exchange of Die, also known as SMED methodology. This paper presents a project of implementing the SMED methodology in the cold profiling process, in a population of five different profiling machines. The results of the SMED implementation show an average OEE improvement of 10,8%.
- Re-dimensioning of a warehouse layout: a practical casePublication . Madureira, Marlene; Sá, José Carlos; Lopes, Manuel Pereira; Ferreira, Luís Pinto; Pereira, Maria TeresaThis study aims to design a new warehouse layout as a solution to the warehouse’s main problem: lack of space to store all the materials in stock. Besides the existing warehouse building, which currently presents an unsuitable layout for the storage of large volumes, there is a second area right next to the first to increase the storage area. The two buildings were re-dimensioned to accommodate a great quantity of stock, enabling one to transform the warehouse building into an industrial warehouse with appropriate storage methods. The final layout increased the storage area by 64%, from a total of 1.471,41 m2 to 2.414,22 m2 overall.
- Lean learning academy: an innovative learning concept in engineering curriculaPublication . Martens, Ignace; Colpaert, Jan; De Boeck, Liesje; Vaz de Carvalho, Carlos; Ávila, Paulo; Lopes, Manuel; Bastos, João; Fonseca, LuísToday, companies are faced with decreasing profit margins due to economic crisis and global competition. At the same time, in many higher educational institutions, students attend rather unattractive courses by sitting and listening to lecturers teaching ex-cathedra. This paper describes how Lean Learning Academy, an innovative training programme on lean manufacturing, can contribute to the competitiveness of companies, to the employability of employees and students, to the motivation of students, and to the attractiveness of engineering curricula. The training programme can be considered as a successful innovative alternative for the traditional way of teaching.
- iLeanDMAIC – A methodology for implementing the lean toolsPublication . Ferreira, C.; Sá, José Carlos; Ferreira, Luís Pinto; Lopes, Manuel P.; Pereira, Maria Teresa; Silva, F.J.G.Organizations focus must reside in their constant desire for improvement in order to satisfy their clients as a result of high-quality products, thus maximizing their profits through a waste reduction in the flow production. Lean thinking allows organizations to identify and eliminate wastes within the organization. The use of lean tools is considered a simple, efficient and cost-effective solution to achieve productivity and profit. DMAIC (Define, Measure, Analyze, Improve, Control) is a problem-solving methodology that improves processes, allows defect reduction and reduction of process variability, allowing companies to continuously improve their efficiency and performance. In this work, a combined methodology iLeanDMAIC based on Lean Tools and DMAIC was developed, aiming to help organizations to easily and accurately solve their problems. It includes a case-study implementation on an organization of the sector of wood products. We were able to successfully validate this methodology and to show its efficacy in enhancing production. Results using iLeanDMAIC allowed a reduction time in changeover in the assembly machine (from 39 min to 17 min), presenting this a 44% gain on manufacture. iLeanDMAIC can help organizations thrive against their competitors, make their business more cost-effective and efficient.