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Abstract(s)
A indústria alimentar tem vindo a apresentar um papel fundamental no quotidiano português. Associado às elevadas preocupações e normas alimentares, existe um ambiente bastante competitivo, ao qual as organizações respondem com estratégias de produção em volume. Estas produções são asseguradas por equipamento avançado e complexo, que necessita de estar em condições de funcionamento ideais, para dar respostas às exigências. Assim, a existência de falhas inesperadas que levem a paragens de emergência na produção e ao incumprimento dos planos produtivos, devem ser evitadas a todo o custo. A correta gestão da manutenção assume um papel crítico para evitar tempos de indisponibilidade e custos associados, conseguindo-se, concomitantemente, melhorar a eficiência global da organização. Este projeto consistiu no desenvolvimento e aplicação de métodos práticos e estruturados, com vista à restruturação da função manutenção na empresa Cerealis - Produtos Alimentares. Após a identificação dos principais problemas e soluções, o trabalho iniciou-se com o desenvolvimento de uma aplicação no ERP (Enterprise Resource Planning). Nesta, constam os vários níveis hierárquicos dos equipamentos, codificados e interligados com outros módulos, possibilitando o desenvolvimento de vários projetos e obtenção de informação fidedigna. Com vista a apoiar a tomada de decisão, foi desenvolvido e implementado um método de classificação da criticidade dos equipamentos com base na sua importância para o processo produtivo, o qual culminou com a classificação dos equipamentos em três categorias (A, B e C). Em função desta, foram definidas estratégias de abordagem por categoria. À “Categoria A” (16,1% dos ativos), foi aplicada uma estratégia de manutenção com base na fiabilidade (RCM - Reliability Centered Maintenance), resultando em análises FMEA (Failure Mode and Effects Analysis) assistidas por uma lógica RCM de 64 equipamentos do grupo. Este estudo detalhado dos equipamentos, constituiu as bases para alterações pontuais nos ativos (ações corretivas) e uma revisão profunda dos Planos de Manutenção Preventiva (PMP) da organização, visando a sua atualização e otimização. Concluído o procedimento anteriormente descrito, podem ser identificadas melhorias significativas ao nível da organização da manutenção motivadas pelo desenvolvimento da aplicação em ERP, “Árvore de Equipamentos”, que possibilitou auxílio aos processos técnicos e de gestão, como o desenvolvimento de indicadores de controlo financeiro. A classificação da criticidade mostrou-se preponderante na tomada de decisão, motivando uma revisão dos PMP, ponderada em função da sua importância para o processo produtivo. Assim, foram registadas lacunas nos PMP que foram identificadas e corrigidas, com resultados quantitativos. Na indústria, o equipamento e processos estão em constante mudança. Assim, uma atualização e melhoria contínua do projeto desenvolvido é fundamental para o seu sucesso sustentado.
The food industry has played a key role in Portuguese daily life. Associated with high food standards and concerns, there is a very competitive environment to which organizations respond with volume production strategies. These productions are ensured by advanced and complex equipment, which needs to be in optimal working conditions, to meet the demands. Thus, unexpected failures leading to emergency stoppages in production and non-compliance with production plans should be avoided at all costs. The correct management of the maintenance assumes a critical role to avoid times of unavailability and associated costs, concomitantly being able to improve the overall efficiency of the organization. This project consisted in the development and application of practical and structured methods, with a view to the restructuring of the maintenance function in the company Cerealis - Produtos Alimentares. After identifying the main problems and solutions, the work began with the development of an application in ERP (Enterprise Resource Planning). In this, the hierarchical levels of the equipment are included, codified and interconnected with other modules, allowing the development of several projects and obtaining reliable information. In order to support decision making, a method of classification of equipment criticality was developed and implemented based on its importance to the production process, which culminated in the classification of equipment into three categories (A, B and C). As a result, category-based approaches have been defined. At Category A (16.1% of the assets), a Reliability Centered Maintenance (RCM) strategy was applied, resulting in FMEA (Failure Mode and Effects Analysis) assisted by the RCM concepts use in 64 equipment of the group. This detailed study of the equipment was the basis for specific changes in the assets (corrective actions) and a thorough review of the organization's Preventive Maintenance Plans (PMP), aiming at their updating and optimization. Following the procedure described above, significant improvements can be identified in the organization of maintenance motivated by the development of the application in ERP, "Equipment Tree", which made it possible to aid technical and management processes, such as the development of financial control indicators. Criticality classification proved to be preponderant in decision making, motivating a review of PMPs, weighted according to their importance to the productive process. Thus, there were gaps identified in the PMPs that were identified and corrected, with quantitative results. In industry, the equipment and processes are constantly changing. Thus, an upgrade and continuous improvement of the project developed is critical to its sustained success.
The food industry has played a key role in Portuguese daily life. Associated with high food standards and concerns, there is a very competitive environment to which organizations respond with volume production strategies. These productions are ensured by advanced and complex equipment, which needs to be in optimal working conditions, to meet the demands. Thus, unexpected failures leading to emergency stoppages in production and non-compliance with production plans should be avoided at all costs. The correct management of the maintenance assumes a critical role to avoid times of unavailability and associated costs, concomitantly being able to improve the overall efficiency of the organization. This project consisted in the development and application of practical and structured methods, with a view to the restructuring of the maintenance function in the company Cerealis - Produtos Alimentares. After identifying the main problems and solutions, the work began with the development of an application in ERP (Enterprise Resource Planning). In this, the hierarchical levels of the equipment are included, codified and interconnected with other modules, allowing the development of several projects and obtaining reliable information. In order to support decision making, a method of classification of equipment criticality was developed and implemented based on its importance to the production process, which culminated in the classification of equipment into three categories (A, B and C). As a result, category-based approaches have been defined. At Category A (16.1% of the assets), a Reliability Centered Maintenance (RCM) strategy was applied, resulting in FMEA (Failure Mode and Effects Analysis) assisted by the RCM concepts use in 64 equipment of the group. This detailed study of the equipment was the basis for specific changes in the assets (corrective actions) and a thorough review of the organization's Preventive Maintenance Plans (PMP), aiming at their updating and optimization. Following the procedure described above, significant improvements can be identified in the organization of maintenance motivated by the development of the application in ERP, "Equipment Tree", which made it possible to aid technical and management processes, such as the development of financial control indicators. Criticality classification proved to be preponderant in decision making, motivating a review of PMPs, weighted according to their importance to the productive process. Thus, there were gaps identified in the PMPs that were identified and corrected, with quantitative results. In industry, the equipment and processes are constantly changing. Thus, an upgrade and continuous improvement of the project developed is critical to its sustained success.
Description
Keywords
Indústria Alimentar Gestão da Manutenção Hierarquia dos Equipamentos Criticidade dos Equipamentos Manutenção Centrada na Fiabilidade Planos de Manutenção Preventiva Indicadores Chave de Desempenho Food Industry Maintenance Management Equipment Hierarchy Equipment Criticality Reliability Centered Maintenance Preventive Maintenance Plans Key Performance Indicators