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Advisor(s)
Abstract(s)
A dissertação apresentada foi realizada num estágio curricular em contexto industrial. O estágio
decorreu entre os meses de setembro de 2022 e junho de 2023 numa empresa de produção de
janelas e portas com estore. Durante estes nove meses, surgiu a oportunidade de integrar a equipa
do PVC, onde foi observado e analisado todo o processo de produção.
A indústria, no geral, tem evoluído numa direção na qual as exigências estão cada vez maiores.
Desta forma, torna-se necessário que haja um maior e melhor controlo sob a produção. Numa era
em que a indústria 4.0 está cada vez mais presente nas fábricas, é imprescindível a existência de
um sistema informático que reúna os dados de produção do chão de fábrica e os disponibilize de
forma organizada com a ajuda de gráficos e indicadores-chave.
A disponibilidade e a fiabilidade de cada equipamento afetam diretamente a produção, quer em
termos de qualidade, quer em termos de prazos a cumprir. Para que uma máquina possa funcionar
corretamente, são necessárias manutenções periódicas que contribuem para o aumento da sua
vida útil. Assim, as manutenções preventivas assumem uma importância fulcral no aumento da
produtividade e redução de desperdício.
O objetivo deste trabalho é a implementação de um sistema que recolha os dados de produção de
cada máquina do chão de fábrica e os disponibilize em tempo real através de um dashboard
operacional. Neste sistema, são registadas quantidades produzidas, ritmos de produção e
quantidade de peças defeituosas. De igual forma, é registado quando um equipamento está em
produção ou em paragem, havendo a necessidade de justificar os tempos de paragens não
planeadas. Estes dados são depois dispostos e resumidos através do Overall Equipment
Effectiveness, OEE.
Em simultâneo, foram criadas fichas de instrução paras as diversas tarefas de manutenção
preventiva relacionadas aos equipamentos, juntamente com um plano anual associado à
periodicidade destas tarefas.
Ao longo deste período, foram utilizadas técnicas e ferramentas maioritariamente associadas ao
Lean Manufacturing, tais como Kaizen, gestão visual, ciclo PDCA e a normalização, com o intuito de
maximizar ganhos com o aumento da eficiência do processo e a redução do desperdício. Estes
ganhos são visualmente representados através de indicadores-chave como o OEE e os dashboards
operacionais.
The presented dissertation was carried out in a curricular internship in industrial context. The internship took place between the months of September 2022 and June 2023 in a company that produces windows and doors with shutters. During these nine months, the opportunity arose to join the PVC team, where the whole production process was observed and analysed. The industry, in general, has evolved in a direction in which the demands are greater and greater. Thus, it becomes necessary to have more and better control over production. In an era in which Industry 4.0 is increasingly present in factories, it is essential to have a computer system that gathers production data from the shop floor and makes it available in an organised way with the help of graphs and key indicators. The availability and reliability of each piece of equipment directly affects production, both in terms of quality and the deadlines to be met. In order for a machine to function correctly, periodic maintenance is necessary, which contributes to increasing its useful life. Thus, preventive maintenance assumes a central importance in increasing productivity and reducing waste. The objective of this work is to implement a system that collects production data from each machine on the shop floor and makes it available in real time through an operational dashboard. In this system, quantities produced, production rhythms and quantity of defective parts are recorded. Likewise, it is recorded when a piece of equipment is in production or stopped, with the need to justify unplanned stoppage times. This data is then arranged and summarised through Overall Equipment Effectiveness, OEE. Simultaneously, instruction sheets were created for the various preventive maintenance tasks related to the equipment, along with an annual plan associated with the periodicity of these tasks. Throughout this period, techniques and tools mainly associated to Lean Manufacturing were used, such as Kaizen, visual management, PDCA cycle and standardisation, in order to maximise gains by increasing process efficiency and reducing waste. These gains are visually represented through key indicators such as OEE and operational dashboards.
The presented dissertation was carried out in a curricular internship in industrial context. The internship took place between the months of September 2022 and June 2023 in a company that produces windows and doors with shutters. During these nine months, the opportunity arose to join the PVC team, where the whole production process was observed and analysed. The industry, in general, has evolved in a direction in which the demands are greater and greater. Thus, it becomes necessary to have more and better control over production. In an era in which Industry 4.0 is increasingly present in factories, it is essential to have a computer system that gathers production data from the shop floor and makes it available in an organised way with the help of graphs and key indicators. The availability and reliability of each piece of equipment directly affects production, both in terms of quality and the deadlines to be met. In order for a machine to function correctly, periodic maintenance is necessary, which contributes to increasing its useful life. Thus, preventive maintenance assumes a central importance in increasing productivity and reducing waste. The objective of this work is to implement a system that collects production data from each machine on the shop floor and makes it available in real time through an operational dashboard. In this system, quantities produced, production rhythms and quantity of defective parts are recorded. Likewise, it is recorded when a piece of equipment is in production or stopped, with the need to justify unplanned stoppage times. This data is then arranged and summarised through Overall Equipment Effectiveness, OEE. Simultaneously, instruction sheets were created for the various preventive maintenance tasks related to the equipment, along with an annual plan associated with the periodicity of these tasks. Throughout this period, techniques and tools mainly associated to Lean Manufacturing were used, such as Kaizen, visual management, PDCA cycle and standardisation, in order to maximise gains by increasing process efficiency and reducing waste. These gains are visually represented through key indicators such as OEE and operational dashboards.
Description
Keywords
Manufacturing Execution System Preventive Maintenance Lean Manufacturing Industry 4 Robotised line