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A presente dissertação de mestrado foi elaborada na CaetanoBus S.A., empresa pertencente ao Grupo Salvador Caetano, no âmbito do Mestrado em Engenharia Química – Energia e Biorrefinaria. Com os avanços na indústria automóvel, as empresas sentem, cada vez mais, a necessidade de se reinventarem a si e aos seus processos com o objetivo de se tornarem mais competitivas num mercado tão diversificado. Nesse sentido, este projeto assumiu como principais objetivos a implementação de ferramentas Toyota e ações de melhoria que visam, sobretudo, eliminar o desperdício, qualquer que seja a sua origem. Os autocarros elétricos de serviço urbano foram os acompanhados no decorrer da atual dissertação. Para responder aos objetivos propostos, foi necessário compreender todo o processo referente à construção do autocarro. Estas operações foram diariamente acompanhadas e cronometradas, no sentido de serem conhecidas na sua totalidade. As cronometragens permitiram balancear a linha de montagem e calcular a eficiência de cada posto de trabalho. Do primeiro ao quinto, respetivamente, a eficiência obtida foi de 68,6 %, 84,7 %, 71,6 %, 88,3 % e 69,4 %. Em seguida, foi possível implementar yamazumis e kamishibais. Por um lado, o yamazumi permite a gestão de um posto de trabalho com base em dados que a comprovem. Por outro lado, o kamishibai permite uma compreensão visual e rápida do estado do produto. Decorrente do acompanhamento diário, surgem diversas ideias de ações de melhoria que visam a otimização das operações. De entre as várias implementadas, apresentaram-se 7. Nas primeiras 2, às quais foi dado maior destaque, registou-se um ganho de 5,6 % de espaço e uma redução de 13,8 % em custos, respetivamente. Em relação às melhorias apresentadas na tabela, na melhoria número 1 e 2 houve uma redução do tempo de tarefa, por essa ordem, igual a 36,7 % e 12,7 %. Na melhoria 3 foi possível reduzir as deslocações e melhorar o aspeto visual do posto. Relativamente à ação número 4, as melhorias foram ao nível ergonómico e de segurança. Por fim, a número 5, permitiu uma redução de 66,7 % no tempo de execução da tarefa. De notar que alguns valores apresentados são meramente fictícios, conforme será referido. Em suma, os resultados evidenciam os desperdícios escondidos nos processos produtivos e realçam a importância da melhoria contínua para um processo cada vez mais eficiente.
This master's thesis was carried out at CaetanoBus S.A., a company belonging to the Salvador Caetano Group, as part of the Master's Degree in Chemical Engineering - Energy and Biorefinery. The automotive industry is constantly growing and changing. For this reason, it is imperative that companies operate in this sector. With this in mind, the main objectives of this project is to apply Toyota tools to the process under study: balancing an assembly line, implementing yamazumis and kamishibais and, finally, optimizing the process by implementing improvements aimed above all at eliminating waste, regardless of its origin. To meet the proposed objectives, it was necessary to understand the entire production process involved in building a city bus. For this purpose, the production process was monitored daily, and timing measurements were taken to balance the finishing section and calculate the efficiency of each station. From the first to the fifth, respectively, the efficiency obtained was 69 %, 85 %, 70 %, 68 % and 75 %. After balancing, it was possible to implement yamazumis and kamishibais. On the one hand, yamazumi allows a job to be managed quickly and visually, by knowing the exact number of employees assigned to that job and their task times. On the other hand, kamishibai fosters responsibility, teamwork and allows a quick and visual understanding of the state of the product. In addition, during the daily monitoring of the process, it was possible to identify opportunities for improvement. Among the various actions implemented, we present 7. In the action relating to the application of vinyl, there was a gain of 5.3 % in the area available at the workstation. The internalization of the fire system saw a gain of 12 % and an increase of 1,481 available working hours. In relation to improvement 1 in Table 4.5, there was a 37 % gain in time. Improvement 2 reduced the task time by 13 %. Improvement 3 reduced travel and visually improved the workstation. For action number 4, the improvements were in terms of ergonomics and safety. The last improvement presented, number 5, resulted in a 67 % time gain. In conclusion, the results show the hidden waste in production processes and highlight the importance of continuous improvement for an increasingly efficient process.
This master's thesis was carried out at CaetanoBus S.A., a company belonging to the Salvador Caetano Group, as part of the Master's Degree in Chemical Engineering - Energy and Biorefinery. The automotive industry is constantly growing and changing. For this reason, it is imperative that companies operate in this sector. With this in mind, the main objectives of this project is to apply Toyota tools to the process under study: balancing an assembly line, implementing yamazumis and kamishibais and, finally, optimizing the process by implementing improvements aimed above all at eliminating waste, regardless of its origin. To meet the proposed objectives, it was necessary to understand the entire production process involved in building a city bus. For this purpose, the production process was monitored daily, and timing measurements were taken to balance the finishing section and calculate the efficiency of each station. From the first to the fifth, respectively, the efficiency obtained was 69 %, 85 %, 70 %, 68 % and 75 %. After balancing, it was possible to implement yamazumis and kamishibais. On the one hand, yamazumi allows a job to be managed quickly and visually, by knowing the exact number of employees assigned to that job and their task times. On the other hand, kamishibai fosters responsibility, teamwork and allows a quick and visual understanding of the state of the product. In addition, during the daily monitoring of the process, it was possible to identify opportunities for improvement. Among the various actions implemented, we present 7. In the action relating to the application of vinyl, there was a gain of 5.3 % in the area available at the workstation. The internalization of the fire system saw a gain of 12 % and an increase of 1,481 available working hours. In relation to improvement 1 in Table 4.5, there was a 37 % gain in time. Improvement 2 reduced the task time by 13 %. Improvement 3 reduced travel and visually improved the workstation. For action number 4, the improvements were in terms of ergonomics and safety. The last improvement presented, number 5, resulted in a 67 % time gain. In conclusion, the results show the hidden waste in production processes and highlight the importance of continuous improvement for an increasingly efficient process.
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Keywords
Lean Production Desperdício Melhorias Produtividade Lean Production Waste Improvements Productivity