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Abstract(s)
A presente dissertação, inserida no Mestrado em Engenharia Química com especialização em Tecnologias de Proteção Ambiental, foi realizada na Brasmar, empresa líder no processamento e comercialização de diversos tipos de pescado. A realização deste trabalho teve como objetivo a análise dos desperdícios na embalagem de cefalópodes e bacalhau nas linhas de Higienização (1, 3 e Nova), linha Flowpack, linha Termoformadora e linha Ensacadora do Setor 2, de forma a identificar medidas para futura implementação, que levem a uma redução do desperdício durante o embalamento. Para satisfazer este objetivo foram usadas as metodologias de melhoria contínua Kaizen onde foram considerados conceitos como “Ir para o Gemba”, a “Gestão Visual”, “Envolver as pessoas”, e o ciclo Plan-Do-Check-Action (PDCA), onde se usaram os diagramas de Ishikawa aliados à fase de planear. Na análise das linhas Higienização (1, 3 e Nova), concluiu-se que grande parte do desperdício de cuvetes se deve ao errado manuseamento das mesmas por parte dos colaboradores, além de problemas pontuais no equipamento, que são resolvidos pela equipa de manutenção. Verificou-se também que o planeamento é um fator primordial à prevenção de desperdício de filme, já que existem filmes de diferentes larguras adequados às cuvetes a embalar e, as mudanças de filme entre ordens de produção originam a perda de dezenas de metros. A sugestão da implementação da comunicação por Walkie-Talkies com os colaboradores que regulam o fluxo de cuvetes também permitirá reduzir os desperdícios de cuvetes e filme nas linhas. Em particular, na linha Higienização Nova, notou-se que para prevenir desperdício de filme era necessária a formação dos colaboradores para a correta colocação do filme na máquina, a colocação de uma etiquetadora automática na linha para colocação de etiquetas na base das cuvetes e a configuração correta do detetor de metais. Na linha Higienização 3, a realização de limpezas frequentes na mordaça prevenirá o se mau funcionamento. Os problemas detetados na linha Flowpack estão relacionados com problemas na selagem das embalagens, defeitos na impressão de informações e com a sobreposição de cuvetes dentro da embaladora devido ao mau funcionamento do sensor. Da observação da linha Termoformadora, concluiu-se que a colocação de um tapete que aumente a aderência das cuvetes ao mesmo permitiria prevenir desperdícios, assim como a resolução do mau funcionamento do sistema de vácuo e impressão de informações nas embalagens. A sensibilização dos colaboradores para evitar desperdícios é importante, já que na linha são desperdiçadas enormes quantidades de embalagens vazias, pelo facto dos trabalhadores não garantirem a colocação do pescado nas posições corretas a tempo. Por fim, o principal desperdício na linha Ensacadora está relacionado com as mudanças de filme, pelo que o correto planeamento das ordens de produção é fundamental, fazendo com que as trocas de filmes sejam realizadas apenas quando se esgota o rolo. A implementação das sugestões apresentadas neste trabalho permitirá uma melhoria quer na eficiência do processo de embalamento, quer na redução do desperdício, proporcionando consequentemente benefícios financeiros para a Brasmar.
This dissertation, inserted in the Master's degree in Chemical Engineering with specialization in Environmental Protection Technologies, was held at Brasmar, a leading company in the processing and commercialization of various types of fish. The objective of this work was to analyze the waste in the cephalopod and cod packaging in the “Higienizaçao” lines (1, 3 and “Nova”), Flowpack line, “Termoformadora” line and Sector 2 “Ensacadora” line, in order to identify measures for future implementation, which lead to a reduction of waste during packaging. To meet this goal, Kaizen continuous improvement methodologies were used where concepts such as “Go to Gemba”, “Visual Management”, “Engaging People”, and the Plan-Do-Check-Action (PDCA) cycle, where Ishikawa diagrams were used together with the planning phase. In the analysis of the “Higienização” lines, it was concluded that much of the waste of ice trays is due to the wrong handling of the same by the employees, in addition to specific problems in the equipment, solved by the maintenance team. It was also found that planning is a key factor in preventing film waste, since there are films of different widths suitable for the cuvettes to pack and, the film changes between production orders lead to the loss of tens of meters. The suggestion of the implementation of communication by Walkie-Talkies with the collaborators who regulate the flow of ice trays will also reduce their waste and film in the line. In particular in the “Higienização nova” line, it was noticed that to prevent waste of film it was necessary to train the collaborators for the correct placement of the film in the machine, the placement of an automatic labeler on the line for placing labels on the base of the ice trays and its required to correct the metal detector. In the “Higienização 3” line, frequent cleaning on the gag prevents its malfunction. The problems found in the Flowpack line are related to problems in sealing the packaging, defects in the printing of information and the overlap of cuvettes inside the packager due to the malfunction of the sensor. From the observation of the “Termoformadora” line, it was concluded that the placement of a carpet that increases the adhesion of the ice trays to it would prevent waste, as well as the resolution of the malfunction of the vacuum system and printing information on the packaging. The awareness of employees to avoid waste is important, since huge amounts of empty packaging are wasted on the line, because workers do not guarantee the placement of the fish in the correct positions on time. Finally, the main waste in the “Ensacadora” line is related to film changes, so the correct planning of production orders is essential, making film changes only due to the end of the roll. The implementation of the suggestions presented in this work will allow an improvement both in the efficiency of the packaging process and in the reduction of waste, providing financial benefits for Brasmar.
This dissertation, inserted in the Master's degree in Chemical Engineering with specialization in Environmental Protection Technologies, was held at Brasmar, a leading company in the processing and commercialization of various types of fish. The objective of this work was to analyze the waste in the cephalopod and cod packaging in the “Higienizaçao” lines (1, 3 and “Nova”), Flowpack line, “Termoformadora” line and Sector 2 “Ensacadora” line, in order to identify measures for future implementation, which lead to a reduction of waste during packaging. To meet this goal, Kaizen continuous improvement methodologies were used where concepts such as “Go to Gemba”, “Visual Management”, “Engaging People”, and the Plan-Do-Check-Action (PDCA) cycle, where Ishikawa diagrams were used together with the planning phase. In the analysis of the “Higienização” lines, it was concluded that much of the waste of ice trays is due to the wrong handling of the same by the employees, in addition to specific problems in the equipment, solved by the maintenance team. It was also found that planning is a key factor in preventing film waste, since there are films of different widths suitable for the cuvettes to pack and, the film changes between production orders lead to the loss of tens of meters. The suggestion of the implementation of communication by Walkie-Talkies with the collaborators who regulate the flow of ice trays will also reduce their waste and film in the line. In particular in the “Higienização nova” line, it was noticed that to prevent waste of film it was necessary to train the collaborators for the correct placement of the film in the machine, the placement of an automatic labeler on the line for placing labels on the base of the ice trays and its required to correct the metal detector. In the “Higienização 3” line, frequent cleaning on the gag prevents its malfunction. The problems found in the Flowpack line are related to problems in sealing the packaging, defects in the printing of information and the overlap of cuvettes inside the packager due to the malfunction of the sensor. From the observation of the “Termoformadora” line, it was concluded that the placement of a carpet that increases the adhesion of the ice trays to it would prevent waste, as well as the resolution of the malfunction of the vacuum system and printing information on the packaging. The awareness of employees to avoid waste is important, since huge amounts of empty packaging are wasted on the line, because workers do not guarantee the placement of the fish in the correct positions on time. Finally, the main waste in the “Ensacadora” line is related to film changes, so the correct planning of production orders is essential, making film changes only due to the end of the roll. The implementation of the suggestions presented in this work will allow an improvement both in the efficiency of the packaging process and in the reduction of waste, providing financial benefits for Brasmar.
Description
Keywords
Desperdício Prevenção Diagramas de Ishikawa Embalagem Pescado Waste Prevention Ice Trays Packaging Film