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Abstract(s)
A presente dissertação, desenvolvida na empresa Solidal – Condutores Eléctricos S. A., empresa produtora de cabos elétricos, teve como principal objetivo a análise do funcionamento de duas linhas de extrusão, para identificação de problemas existentes e posteriormente serem implementadas melhorias para eliminar a incidência dos mesmos. Toda a análise e identificação de propostas de melhoria teve por base conceitos, metodologia e ferramentas Lean, tais como o SMED, 5S e Manutenção Autónoma, tendo em atenção o foco na redução de todas as ineficiências existentes e direcionamento de esforços para o potenciamento das linhas em análise. Após a identificação dos problemas e implementação de melhorias para os eliminar, foi vez de analisar os resultados. Foram alcançados ganhos em variados níveis: espaço, tempo, qualidade de trabalho, etc. Com a aplicação dos 5S (e a sua auditoria semanal) foi possível atingir um espaço de trabalho limpo, organizado e seguro, tal como desejável. Através da aplicação da metodologia SMED obteve-se uma redução média de 39% para a linha CV01 e 28% para a linha CV02, no que diz respeito aos tempos médios previstos para realização das variadas tipologias de setup (isto numa comparação dos standards de setup antigos vs atualizados pós-melhorias). Para o ano de 2021 já foi possível visualizar uma redução do tempo médio por setup. A criação de OPL’s permite agora a realização das tarefas da forma correta, evitando erros ou variações no procedimento de realização das mesmas. A monitorização das linhas, com o acompanhamento dos setups por parte dos coordenadores de setups, permite a análise e perceção em tempo real dos resultados atingidos e de possíveis dificuldades sentidas. A análise de investimentos possibilitou a perceção dos ganhos que certos equipamentos poderão trazer para as linhas em estudo. A implementação da Manutenção Autónoma permitirá a longo prazo reduzir custos de manutenção, reduzir os tempos de paragem associados à correção de avarias, e permitir um melhor acompanhamento das linhas. Por fim, e fruto de todas as melhorias implementadas, o OEE que no ano de 2020 estava no patamar dos 50%, aumentou agora para o patamar dos 60%, em ambas as linhas, mostrando assim um caminho de melhoria e ganhos percetíveis, tal como desejável desde o primeiro dia de realização do projeto.
The main objective of this dissertation, developed at Solidal – Condutores Eléctricos SA, a company that produces electrical cables, was to analyze the operation of two extrusion lines, to identify existing problems and subsequently implement improvements to eliminate the incidence of same. The entire analysis and identification of improvement proposals was based on Lean concepts, methodology and tools, such as SMED, 5S and Autonomous Maintenance, considering the focus on reducing all existing inefficiencies and directing efforts to enhance lines under analysis. After identifying the problems and implementing improvements to eliminate them, it was time to analyze the results. Gains were achieved at various levels: space, time, quality of work, etc. With the application of 5S (and its weekly audit) it was possible to achieve a clean, organized and safe workspace, as desired. Through the application of the SMED methodology, an average reduction of 39% for the CV01 line and 28% for the CV02 line was obtained, with regard to the average times expected to carry out the various types of setup (this in a comparison of old setup standards vs updated postimprovements). For the year 2021 it was already possible to see a reduction in the average time per setup. The creation of OPL's now allows the tasks to be carried out correctly, avoiding errors or variations in the procedure for carrying them out. The monitoring of the lines, with the follow-up of the setups by the setup coordinators, allows real-time analysis and perception of the results achieved and possible difficulties experienced. The investment analysis made it possible to perceive the gains that certain equipment could bring to the lines under study. The implementation of Autonomous Maintenance will, in the long term, reduce maintenance costs, reduce downtime associated with the correction of faults, and allow for better monitoring of the lines. Finally, and as a result of all the improvements implemented, the OEE, which in 2020 was at the level of 50%, has now increased to the level of 60%, in both lines, thus showing a path of improvement and noticeable gains, such as desirable from day one of the project.
The main objective of this dissertation, developed at Solidal – Condutores Eléctricos SA, a company that produces electrical cables, was to analyze the operation of two extrusion lines, to identify existing problems and subsequently implement improvements to eliminate the incidence of same. The entire analysis and identification of improvement proposals was based on Lean concepts, methodology and tools, such as SMED, 5S and Autonomous Maintenance, considering the focus on reducing all existing inefficiencies and directing efforts to enhance lines under analysis. After identifying the problems and implementing improvements to eliminate them, it was time to analyze the results. Gains were achieved at various levels: space, time, quality of work, etc. With the application of 5S (and its weekly audit) it was possible to achieve a clean, organized and safe workspace, as desired. Through the application of the SMED methodology, an average reduction of 39% for the CV01 line and 28% for the CV02 line was obtained, with regard to the average times expected to carry out the various types of setup (this in a comparison of old setup standards vs updated postimprovements). For the year 2021 it was already possible to see a reduction in the average time per setup. The creation of OPL's now allows the tasks to be carried out correctly, avoiding errors or variations in the procedure for carrying them out. The monitoring of the lines, with the follow-up of the setups by the setup coordinators, allows real-time analysis and perception of the results achieved and possible difficulties experienced. The investment analysis made it possible to perceive the gains that certain equipment could bring to the lines under study. The implementation of Autonomous Maintenance will, in the long term, reduce maintenance costs, reduce downtime associated with the correction of faults, and allow for better monitoring of the lines. Finally, and as a result of all the improvements implemented, the OEE, which in 2020 was at the level of 50%, has now increased to the level of 60%, in both lines, thus showing a path of improvement and noticeable gains, such as desirable from day one of the project.
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Keywords
Lean Manufacturing SMED OEE 5S Setup Manutenção Autónoma Melhoria Contínua Autonomous Maintenance Continuous Improvement