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Advisor(s)
Abstract(s)
A competitividade no setor automóvel tem vindo a aumentar devido à crescente sofisticação do mercado bem como à constante mudança nas preferências e requisitos dos clientes. Para se manterem competitivas, as organizações procuram formas de se tornar mais responsivas e flexíveis. Neste sentido, há uma crescente preocupação em assegurar um sistema de abastecimento de componentes bem estruturado e eficiente, tanto a nível externo como interno que esteja alinhado com a filosofia Just-In-Time e com os princípios Lean, evitando desperdícios e contornando a variabilidade associada ao setor. Esta variabilidade decorre não só da crescente diferenciação dos produtos que leva à adoção de multi and mixed model assembly lines como da incerteza e variação na procura dos clientes resultante do aparecimento do surto de um novo coronavirus (COVID-19) a nível mundial. O presente projeto de dissertação, conduzido através da metodologia Action-Research (AR), foi realizado na Gestamp Palau S.A., empresa a operar no setor automóvel, e centrou-se na melhoria da performance do sistema milk run de abastecimento interno de componentes ao departamento de soldadura. Foram detetadas várias problemáticas que estariam a comprometer a eficiência deste serviço logístico entre as quais a falta de estudo e documentação de fluxos de materiais bem como das operações a serem desempenhadas pelos trabalhadores e a sua quantificação temporal. A existência destes problemas traduzia-se na dificuldade de planeamento e gestão dos recursos (humanos e materiais) necessários para desempenhar o serviço de abastecimento de componentes às células de soldadura. As ações levadas a cabo para abordar todos os problemas identificados, culminaram no desenvolvimento de uma ferramenta de simulação e apoio à decisão na gestão do sistema de abastecimento de componentes. Esta tem como principal objetivo facilitar, a curto ou a longo prazo, o planeamento e balanceamento da equipa logística bem como a gestão dos materiais movimentados consoante a variação da carga de trabalho causada pelas diferentes situações de procura ao departamento de soldadura. A análise realizada às simulações feitas com recurso à ferramenta e em conjunto com o departamento de logística e o especialista do estudo dos tempos, revelou que esta produzia resultados fiáveis, objetivos e devidamente ajustados às variações da procura dos clientes bem como ao mix de produtos e componentes existentes no departamento de soldadura. Assim, é expectável um aumento da eficiência do serviço de abastecimento de componentes às células de soldadura uma vez que o planeamento e gestão dos recursos humanos necessários é feito de forma dinâmica, flexível e balanceada evitando sub ou sobre aproveitamento dos mesmos. Para além disto, existe uma maior perceção dos materiais a ser movimentados, da carga de trabalho individual que cada atividade representa no trabalho dos operadores bem como dos diferentes tempos de reaprovisionamento (lead times) necessários consoante cada instância de produção. Atualmente é estudada a implementação oficial da ferramenta na Gestamp Palau como uma metodologia para potenciar a eficiência do sistema de abastecimento ao departamento de soldadura, assim como a sua extensão a outros fluxos internos com características semelhantes.
Competitiveness in the automotive sector has been increasing due to the growing sophistication of the market as well as the constant change in customer preferences and requirements. To stay competitive, organizations look for ways to become more responsive and flexible. In this sense, there is a growing concern to ensure a well-structured and efficient component supply system, both externally and internally, in line with Just-In-Time philosophy and Lean principles, avoiding waste and circumventing the variability associated with the sector. This variability arises not only from the growing differentiation of products that lead to the adoption of multi and mixed model assembly lines, but also from the uncertainty and variation in customer demand resulting from the emergence of the outbreak of a new coronavirus (COVID-19) worldwide. This dissertation project, conducted through the Action-Research (AR) methodology, was carried out at Gestamp Palau S.A., a company operating in the automotive sector, and focused on improving the performance of the milk run system for internal supply of components to the welding department. Several problems were detected that could compromise the efficiency of this logistic service, including the lack of study and documentation of material flows as well as the operations to be performed by the workers and their temporal quantification. The existence of these problems resulted in the difficulty on planning and managing the necessary resources (human and material) to perform the service of supplying components to the welding cells. The actions taken to address all the problems identified, culminated in the development of a simulation and decision support tool for the component supply system management. Its main objective is to facilitate, in the short or long term, the planning and balancing of the logistic team, as well as the management of the materials handled depending on the variation in the workload caused by the different situations demand to the welding department. The analysis carried out on the different simulations made using the tool, together with the logistics department and the specialist in the study of times, revealed that it produced reliable, objective and adjusted results to variations in customer demand as well as to the existing product mix in the welding department. Thus, an increase in the efficiency of the service of supplying components to the welding cells is expected, since the planning and management of the necessary human resources is done in a dynamic, flexible and balanced way, avoiding its under or overutilization. In addition, there is a greater perception of the materials to be handled, of the individual workload that each activity represents in the operators' work, as well as of the different replenishment lead times needed according to each production instance. Currently, the official implementation of the tool at Gestamp Palau is being studied as a methodology to enhance the efficiency of the parts feeding system to the welding department, as well as the possibility to extend it to other internal flows with similar characteristics.
Competitiveness in the automotive sector has been increasing due to the growing sophistication of the market as well as the constant change in customer preferences and requirements. To stay competitive, organizations look for ways to become more responsive and flexible. In this sense, there is a growing concern to ensure a well-structured and efficient component supply system, both externally and internally, in line with Just-In-Time philosophy and Lean principles, avoiding waste and circumventing the variability associated with the sector. This variability arises not only from the growing differentiation of products that lead to the adoption of multi and mixed model assembly lines, but also from the uncertainty and variation in customer demand resulting from the emergence of the outbreak of a new coronavirus (COVID-19) worldwide. This dissertation project, conducted through the Action-Research (AR) methodology, was carried out at Gestamp Palau S.A., a company operating in the automotive sector, and focused on improving the performance of the milk run system for internal supply of components to the welding department. Several problems were detected that could compromise the efficiency of this logistic service, including the lack of study and documentation of material flows as well as the operations to be performed by the workers and their temporal quantification. The existence of these problems resulted in the difficulty on planning and managing the necessary resources (human and material) to perform the service of supplying components to the welding cells. The actions taken to address all the problems identified, culminated in the development of a simulation and decision support tool for the component supply system management. Its main objective is to facilitate, in the short or long term, the planning and balancing of the logistic team, as well as the management of the materials handled depending on the variation in the workload caused by the different situations demand to the welding department. The analysis carried out on the different simulations made using the tool, together with the logistics department and the specialist in the study of times, revealed that it produced reliable, objective and adjusted results to variations in customer demand as well as to the existing product mix in the welding department. Thus, an increase in the efficiency of the service of supplying components to the welding cells is expected, since the planning and management of the necessary human resources is done in a dynamic, flexible and balanced way, avoiding its under or overutilization. In addition, there is a greater perception of the materials to be handled, of the individual workload that each activity represents in the operators' work, as well as of the different replenishment lead times needed according to each production instance. Currently, the official implementation of the tool at Gestamp Palau is being studied as a methodology to enhance the efficiency of the parts feeding system to the welding department, as well as the possibility to extend it to other internal flows with similar characteristics.
Description
Keywords
Sistema de abastecimento de componentes Milk run Eficiência Força de trabalho Carga de trabalho Variabilidade Ferramenta de simulação e apoio à decisão Parts feeding systems Efficiency Workforce Variability Simulation and decision support tool