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Abstract(s)
Devido à rápida globalização dos automóveis, a indústria automóvel desenvolveu uma elevada
competitividade entre as empresas que operam neste meio e que, por consequência, procuram
uma constante melhoria dos seus processos que permite aumentar a produtividade destes e a
qualidade das peças produzidas. A melhoria contínua dos produtos desenvolvidos e dos
processos de fabrico praticados resulta na elevada relevância da indústria automóvel a nível
mundial, não só pela sua abrangência global, como pelo desenvolvimento tecnológico que
impulsiona. Entre estas empresas encontra-se a Gestamp Aveiro que, numa perspetiva de
melhoria contínua do seu processo de estampagem, identificou a queda de produtividade
provocada pelos sistemas transfer, principalmente devido a ajustes e avarias, e assim a
oportunidade de melhoria que esta representava. Neste sentido desenvolveu-se o trabalho de
melhoria de produtividade dos sistemas transfer dentro da Gestamp Aveiro, como empresa de
acolhimento para esta dissertação. O trabalho desenvolvido seguiu a metodologia Design
Science Research e começou pela análise do sistema transfer e do processo de estampagem
transfer, seguida da identificação das ocorrências causadoras da produtividade insatisfatória e
da definição de hipóteses de melhoria para estas. Das hipóteses de melhoria foram
selecionadas e desenvolvidas o projeto de uma estrutura para medição da posição de sistemas
transfer fora da prensa, o projeto da redução do tamanho das sobrebarras e o projeto de uma
nova solução construtiva de sistemas transfer, que envolveu o design e estudo de novos
componentes fabricados por impressão 3D. As soluções desenvolvidas permitiram mitigar as
ocorrências que implicam a baixa produtividade, reduzindo o número de avarias e a
necessidade de ajustes do sistema transfer durante as produções. A aplicação destas soluções
não implica uma paragem da produção nem do funcionamento normal do processo de
estampagem e consegue uma melhoria de produtividade dos sistemas transfer. Desta forma,
além de atingir o objetivo da empresa de acolhimento, é possível obter um retorno do
investimento realizado por esta num prazo satisfatório.
Due to the rapid globalization of automobiles, the automotive industry has developed a high level of competitiveness among the companies that operate in this sector and, as a result, are constantly seeking to improve their processes to increase their productivity and the quality of the produced parts. The continuous improvement of the developed products and the practiced manufacturing processes results in the automotive industry's high relevance worldwide, not only because of its global reach, but also because of the technological development it drives. Among these companies is Gestamp Aveiro, which, with a view to continuous improvement in its stamping process, identified the drop in productivity caused by transfer systems, mainly due to adjustments and breakdowns, and thus the opportunity for improvement that this productivity drop represented. To this end, the present work was carried out to improve the productivity of transfer systems within Gestamp Aveiro, as the host company for this dissertation. The work carried out followed the Design Science Research methodology and began by analysing the transfer system and the transfer stamping process, followed by identifying the events that caused unsatisfactory productivity and defining hypotheses for improvement. Between the hypotheses for improvement, the following were selected and developed: the design of a structure to measure the position of transfer systems outside the press, the design of a reduction in the size of overbars, and the design of a new construction solution for transfer systems, this last involving the design and study of new components manufactured using 3D printing. The developed solutions made it possible to mitigate the occurrences that lead to low productivity, reducing the number of breakdowns and the need to adjust the transfer system during production. The application of these solutions does not involve stopping the production nor the normal operation of the stamping process and promotes an improvement in the productivity of the transfer systems. In this way, the host company's objective is met, and it is also possible to obtain a return on its investment within a satisfactory timeframe.
Due to the rapid globalization of automobiles, the automotive industry has developed a high level of competitiveness among the companies that operate in this sector and, as a result, are constantly seeking to improve their processes to increase their productivity and the quality of the produced parts. The continuous improvement of the developed products and the practiced manufacturing processes results in the automotive industry's high relevance worldwide, not only because of its global reach, but also because of the technological development it drives. Among these companies is Gestamp Aveiro, which, with a view to continuous improvement in its stamping process, identified the drop in productivity caused by transfer systems, mainly due to adjustments and breakdowns, and thus the opportunity for improvement that this productivity drop represented. To this end, the present work was carried out to improve the productivity of transfer systems within Gestamp Aveiro, as the host company for this dissertation. The work carried out followed the Design Science Research methodology and began by analysing the transfer system and the transfer stamping process, followed by identifying the events that caused unsatisfactory productivity and defining hypotheses for improvement. Between the hypotheses for improvement, the following were selected and developed: the design of a structure to measure the position of transfer systems outside the press, the design of a reduction in the size of overbars, and the design of a new construction solution for transfer systems, this last involving the design and study of new components manufactured using 3D printing. The developed solutions made it possible to mitigate the occurrences that lead to low productivity, reducing the number of breakdowns and the need to adjust the transfer system during production. The application of these solutions does not involve stopping the production nor the normal operation of the stamping process and promotes an improvement in the productivity of the transfer systems. In this way, the host company's objective is met, and it is also possible to obtain a return on its investment within a satisfactory timeframe.
Description
Keywords
Design science research methodology Mechanical design Automotive industry Productivity Stamping process Transfer systems Metodologia design science research Projeto mecânico Indústria automóvel Produtividade Processo de estampagem Sistemas transfer