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Melhoria do processo produtivo de rolhas naturais: aplicação do Value Stream Mapping
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Resumo(s)
A cortiça é uma matéria‐prima sustentável, com características únicas, que representa
um significativo impacto comercial e financeiro na economia de Portugal, sendo
amplamente utilizada numa grande diversidade de produtos e mercados, cujo destino
mais comum é a produção de rolhas.
Ao longo dos anos, o mercado de rolhas de cortiça tem exigido às empresas um
elevado nível de qualidade e flexibilidade na produção, o que cria a necessidade das
mesmas em apostar na melhoria contínua dos processos produtivos, para que possam
permanecer no mercado e se tornarem competitivas.
Neste sentido, a Cork Supply Portugal, atualmente um dos maiores produtores de
rolhas de cortiça a nível global, a qual serviu de caso de estudo para esta dissertação,
tem vindo a investir constantemente na melhoria contínua, na inovação e na
investigação.
O presente projeto enquadra‐se numa perspetiva de melhorar o processo produtivo de
rolhas naturais, a eficiência e prazo de entrega do produto ao cliente, através da
aplicação de ferramentas de melhoria contínua.
O método aplicado consistiu na recolha e análise de informação sobre a filosofia Lean
Production, no processo produtivo de rolhas naturais e operações associadas. Neste
seguimento, foi elaborado o VSM (Value Stream Mapping) produtivo de rolhas
naturais, com o objetivo de analisar o fluxo de materiais e informações necessários
para levar um produto a um cliente, permitindo identificar oportunidades de melhoria
e para eliminar as atividades de valor não acrescentado.
De forma a monitorizar todo o desenvolvimento do VSM produtivo de rolhas naturais,
elaborou‐se um relatório A3.
Os resultados obtidos comprovam um decréscimo no valor total de inventário após
quatro meses do momento da implementação das ações de melhoria, uma diminuição
da diferenciação do inventário, que potenciou o aumentando da disponibilidade de
rolhas no estado natural, e uma diminuição nos movimentos internos logísticos em
mais de 10%.
Cork is a sustainable raw material with unique characteristics that represents a significant commercial and financial impact on Portuguese economy, being widely used in several products and markets, whose most common purpose is the production of cork stoppers. Over the years, the cork stopper market has demanded from companies a production with high level of quality and flexibility, which creates the need for them to invest in the continuous improvement of production processes, so that they can remain in the market and become competitive. Thus, Cork Supply Portugal, currently one of the worldwide largest producers of cork stoppers, which served as a case study for this dissertation, has been constantly investing in continuous improvement, innovation and research. This project is part of a perspective of improving the production process of natural cork stoppers, the efficiency and product delivery time to the customer, through the application of continuous improvement tools. The applied method was collecting and analyzing information regarding Lean Production philosophy, in the production process of natural cork stoppers and associated operations. Thus, it was prepared the VSM (Value Stream Mapping) for the production of natural cork stoppers in order to analyze the flow of materials and information needed to take a product to a customer, allowing the identification of opportunities for improvement to remove non‐added value activities. In order to monitor the entire development of the productive VSM of natural cork stoppers, it was prepared an A3 report. The results obtained reveal a decrease in the total inventory value after four months of the improvement actions implementation, a decrease in inventory differentiation, which boosted the increased of natural stoppers availability, and a decrease above 10% of internal logistical movements.
Cork is a sustainable raw material with unique characteristics that represents a significant commercial and financial impact on Portuguese economy, being widely used in several products and markets, whose most common purpose is the production of cork stoppers. Over the years, the cork stopper market has demanded from companies a production with high level of quality and flexibility, which creates the need for them to invest in the continuous improvement of production processes, so that they can remain in the market and become competitive. Thus, Cork Supply Portugal, currently one of the worldwide largest producers of cork stoppers, which served as a case study for this dissertation, has been constantly investing in continuous improvement, innovation and research. This project is part of a perspective of improving the production process of natural cork stoppers, the efficiency and product delivery time to the customer, through the application of continuous improvement tools. The applied method was collecting and analyzing information regarding Lean Production philosophy, in the production process of natural cork stoppers and associated operations. Thus, it was prepared the VSM (Value Stream Mapping) for the production of natural cork stoppers in order to analyze the flow of materials and information needed to take a product to a customer, allowing the identification of opportunities for improvement to remove non‐added value activities. In order to monitor the entire development of the productive VSM of natural cork stoppers, it was prepared an A3 report. The results obtained reveal a decrease in the total inventory value after four months of the improvement actions implementation, a decrease in inventory differentiation, which boosted the increased of natural stoppers availability, and a decrease above 10% of internal logistical movements.
Descrição
Palavras-chave
Cortiça Rolhas Naturais Lean Kaizen Redução de Desperdício Ferramenta A3 VSM Sistema de Produção Toyota Cork Cork stoppers Lean Kaizen Waste reduction A3 report Toyota production system