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Advisor(s)
Abstract(s)
Esta dissertação foi realizada no âmbito do Mestrado em Engenharia e Gestão Industrial da Escola Superior de Estudos Industriais e de Gestão, do Instituto Politécnico do Porto, e desenvolvida em ambiente industrial na empresa IKEA Industry Portugal. O tema do projeto surgiu com a necessidade da empresa melhorar os resultados da rejeição de peças com defeitos que são submetidas a
retrabalho, nomeadamente em linhas de produção de pintura spray. Para este projeto, foi estudado o defeito impurezas, crítico para a qualidade.
De maneira a atingir esse objetivo, realizou-se uma revisão crítica da literatura, que permitiu percebercom a utilização das ferramentas Lean Production (Kaizen, 5´S, TPM´S, OEE, SMED, entre outras), o que se deve monitorizar, e acima de tudo o plano de atuação para que a redução de peças com o defeito impurezas seja reduzido.
Após caraterização do processo produtivo das linhas de produção de pintura spray, definiram-se as possíveis causas, que podem estar na origem do aparecimento do defeito impurezas e que foram monitorizáveis através do registo de ocorrências. Estes registos foram recolhidos no período temporal de novembro de 2015 a julho de 2016.
Este registo das ocorrências foi submetido a testes estatísticos, de modo a testar a hipótese queexiste pelo menos uma relação entre o aparecimento de impurezas nas peças, no que respeita a fatores ambientais, máquina, método (processo), mão-de-obra, e matéria-prima (tinta e MDF).Através desta análise, confirmou-se que as impurezas são uma evidência de desvio de processo em linhas de pintura spray, uma vez que variáveis como a gramagem da tinta, viscosidade, temperatura ambiente, humidade Box e ambiente, caudal de insuflação e extração, e temperatura da tinta contribuem para o aparecimento deste defeito. Finda esta análise, foram implementadas várias soluções de melhorias tecnológicas no processo produtivo e o estabelecimento de rotinas de limpeza das cabines de
pintura, as quais possibilitaram um decréscimo de 9 vezes o número de peças com impurezas no período temporal de um ano, e um ganho monetário de aproximadamente 12000€ por semana, 624000€ por ano.
This dissertation was held within the framework of the master's degree in Industrial Engineering and management from the Escola Superior de Estudos Industriais e de Gestão, Instituto Politécnico do Porto, and developed in an industrial environment in Portugal IKEA Industry. The theme of the project came from the necessityof the company to improve the results of the rejection of defective parts that are subjected to rework, in particular on production lines of spray painting. For this project, it was studied the defect impurities, critical to quality. In order to reach that goal, a critical review of the literature, which allowed perceiving with the use of Lean Production tools (Kaizen, 5 S, TPM ´S, OEE, SMED, among others), monitor, and above all the plan of action for the reduction of parts with the defect impurities are reduced. After characterization of the productive process of production lines for spray painting, defined the possible causes, which may be at the origin of the appearance of defects and impurities that were monitorable by registering. These records were collected in November 2015 time period to July 2016. This register of occurrences was subjected to statistical tests, in order to test the hypothesis that there is at least one link between the appearance of impurities in parts, with regard to environmental factors, machine, method (process), labor, and raw material (ink and MDF).Through this analysis, it was confirmed that the impurities are evidence of abuse of process in spray painting lines, since variables such as the weight of the Ink viscosity, room temperature, humidity and environment, inflation rate and extraction, and ink temperature contribute to the emergence of this defect. After this analysis, various solutions were implemented to technological improvements in the production process and the establishment of cleaning routines of paint booths, which allowed a decrease of 9 times less the number of pieces with impurities in the time period of one year, and a monetary gain of approximately 12000 € for week, 624000 € for year.
This dissertation was held within the framework of the master's degree in Industrial Engineering and management from the Escola Superior de Estudos Industriais e de Gestão, Instituto Politécnico do Porto, and developed in an industrial environment in Portugal IKEA Industry. The theme of the project came from the necessityof the company to improve the results of the rejection of defective parts that are subjected to rework, in particular on production lines of spray painting. For this project, it was studied the defect impurities, critical to quality. In order to reach that goal, a critical review of the literature, which allowed perceiving with the use of Lean Production tools (Kaizen, 5 S, TPM ´S, OEE, SMED, among others), monitor, and above all the plan of action for the reduction of parts with the defect impurities are reduced. After characterization of the productive process of production lines for spray painting, defined the possible causes, which may be at the origin of the appearance of defects and impurities that were monitorable by registering. These records were collected in November 2015 time period to July 2016. This register of occurrences was subjected to statistical tests, in order to test the hypothesis that there is at least one link between the appearance of impurities in parts, with regard to environmental factors, machine, method (process), labor, and raw material (ink and MDF).Through this analysis, it was confirmed that the impurities are evidence of abuse of process in spray painting lines, since variables such as the weight of the Ink viscosity, room temperature, humidity and environment, inflation rate and extraction, and ink temperature contribute to the emergence of this defect. After this analysis, various solutions were implemented to technological improvements in the production process and the establishment of cleaning routines of paint booths, which allowed a decrease of 9 times less the number of pieces with impurities in the time period of one year, and a monetary gain of approximately 12000 € for week, 624000 € for year.
Description
Keywords
Processo Impurezas Pintura spray Lean production Ocorrências Process Impurities Spray painting Occurrences