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Abstract(s)
A indústria automóvel e de fabrico de componentes automóveis é um dos setores com maior impacto na economia de muitos dos países da União Europeia. Devido à elevada competitividade que caracteriza o setor automóvel e à enorme variedade de processos inerentes à produção dos mais variados componentes, existe uma procura intensiva por melhorias que se traduzam em impactos significativos na produtividade dos referidos processos, garantindo ainda assim os níveis de qualidade exigidos pelo cliente. Neste contexto, insere-se também o fabrico de cabos de comando, que nos últimos anos tem sido alvo de inúmeros casos de estudo para melhoria do processo.
O trabalho desenvolvido na presente dissertação teve por base uma necessidade identificada pela empresa Fico Cables, relativa à melhoria da produtividade de um equipamento de fabrico de cabos de comando para a indústria automóvel. O principal objetivo está relacionado com o desenvolvimento de um novo conceito de máquina de decapar que permita remover o revestimento de dois cabos em simultâneo, eliminando assim um gargalo existente no processo de injeção do primeiro terminal de ZAMAK. Foi construído um protótipo da referida máquina e validado o novo conceito, procedendo-se depois à sua implementação na fábrica. Foi ainda projetado um sistema automático de extração de cabo com vista a reduzir a quantidade de tarefas manuais realizadas pelo operador, esperando-se com este sistema mais uma melhoria de produtividade no processo. O desenvolvimento dos dois novos mecanismos abordados no presente trabalho seguiu a metodologia Design Science Research (DSR).
Com a implementação do novo conceito de máquina de decapar dupla, verificou-se um aumento de produtividade de 62,4% no posto de injeção de ZAMAK, que se refletiu em poupanças anuais na ordem dos 42614€. Relativamente ao sistema automático de extração de cabo, estimam-se ganhos de produtividade adicionais de 15,6%. Sendo assim, com a implementação conjunta das duas melhorias estima-se atingir um aumento de produtividade total na ordem dos 87,8%, com uma poupança anual de 51816€
The automotive and automotive component manufacturing industry is one of the sectors with highest impact on the economy of many European Union countries. Due to the high competitiveness that characterizes the automotive sector and the enormous variety of processes inherent to the production of the most varied components, there is an intensive search for improvements that translate into significant impacts on the productivity of these processes, still guaranteeing the levels of quality required by the client. In this context, there is also the manufacture of control cables, which in recent years has been the subject of numerous case studies to improve the process. The work developed in this dissertation was based on a need identified by the company Fico Cables, regarding the improvement of the productivity of a control cable manufacturing equipment for the automotive industry. The main objective is related to the development of a new stripping machine concept that allows the coating removal from two cables simultaneously, thus eliminating an existing bottleneck in the injection process of the first ZAMAK terminal. A prototype of the aforementioned machine was built, and the new concept validated, and then implemented in the factory. An automatic cable extraction system was also designed aiming to reduce the number of manual tasks performed by the operator, with the expectation of further improving the productivity of the process. The development of the two new mechanisms discussed in the present work followed the Design Science Research (DSR) methodology. With the implementation of the new double stripper concept, a 62.4% increase in productivity at the ZAMAK injection station was found, which was reflected in annual savings of around €42,614. Regarding the automatic cable extraction system, additional productivity gains of 15.6% are estimated. Therefore, with the joint implementation of the two improvements, an increase in total productivity of around 87.8% is expected, with annual savings of €51,816
The automotive and automotive component manufacturing industry is one of the sectors with highest impact on the economy of many European Union countries. Due to the high competitiveness that characterizes the automotive sector and the enormous variety of processes inherent to the production of the most varied components, there is an intensive search for improvements that translate into significant impacts on the productivity of these processes, still guaranteeing the levels of quality required by the client. In this context, there is also the manufacture of control cables, which in recent years has been the subject of numerous case studies to improve the process. The work developed in this dissertation was based on a need identified by the company Fico Cables, regarding the improvement of the productivity of a control cable manufacturing equipment for the automotive industry. The main objective is related to the development of a new stripping machine concept that allows the coating removal from two cables simultaneously, thus eliminating an existing bottleneck in the injection process of the first ZAMAK terminal. A prototype of the aforementioned machine was built, and the new concept validated, and then implemented in the factory. An automatic cable extraction system was also designed aiming to reduce the number of manual tasks performed by the operator, with the expectation of further improving the productivity of the process. The development of the two new mechanisms discussed in the present work followed the Design Science Research (DSR) methodology. With the implementation of the new double stripper concept, a 62.4% increase in productivity at the ZAMAK injection station was found, which was reflected in annual savings of around €42,614. Regarding the automatic cable extraction system, additional productivity gains of 15.6% are estimated. Therefore, with the joint implementation of the two improvements, an increase in total productivity of around 87.8% is expected, with annual savings of €51,816
Description
Keywords
Indústria Automóvel Projeto Mecânico Método de Elementos Finitos Cabos de comando Produtividade Metodologia Design Science Research Automotive Industry Mechanical Design Finite Element Method Control Cables Productivity Design Science Research Methodology