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Abstract(s)
A competitividade existente na indústria implica que as empresas tenham de se reinventar. As vantagens competitivas são instáveis e, por isso, é necessário que as empresas se esforcem diariamente para melhorar, de modo a serem mais eficientes e produtivas. Este relatório apresenta um projeto desenvolvido numa empresa responsável pelo fabrico e transformação de compósitos com cortiça, numa área responsável pela aglomeração de cilindros de cortiça com borracha. A crescente procura por este tipo de produtos resultou na necessidade de aumentar significativamente o output da produção. A metodologia utilizada foi o PDCA, centrando a primeira fase na análise do processo produtivo e registo dos principais modos de falha e dificuldades, através da observação da produção e de entrevistas informais com os operadores. Foram utilizadas técnicas Lean para a organização e priorização dos problemas registados e também para o desenvolvimento das ações melhoria. Os maiores problemas estavam relacionados com a grande quantidade de intervenções de manutenção corretiva, que reduziam o tempo útil de produção, e com práticas e parâmetros de produção pouco eficientes. Tendo em consideração os problemas identificados, foram desenvolvidas ações de melhoria, como a criação de folhas de controlo operacional, a alteração de comportamentos e de parâmetros do processo, a alteração de certos equipamentos e a implementação de planos de manutenção autónoma. Com o desenvolvimento das melhorias e tendo em conta o objetivo principal do projeto de aumento do output da produção da linha, foi possível aumentar o output de um tipo de cilindros, não sendo o mesmo verificado para o outro, devido às mudanças da equipa durante a realização do projeto.
Increase of the output of a cork with rubber cylinder production line The competitiveness within the industry implies that companies must reinvent themselves. Competitive advantages are unstable, and therefore, companies need to strive daily to improve in order to be more efficient and productive. This report presents a project developed in a company responsible for the manufacture and processing of cork composites, in an area responsible for the agglomeration of cork cylinders with rubber. The growing demand for this type of product resulted in the need to significantly increase the production output. The methodology used was PDCA, focusing the first phase on analyzing the production process and recording the main failure modes and difficulties, through observation of production and informal interviews with operators. Lean techniques were used for organizing and prioritizing the recorded problems and also for the development of improvement actions. The major problems were related to the large number of corrective maintenance activities, which reduced the useful production time, and inefficient production practices and parameters. Taking into consideration the identified problems, improvement actions were developed, such as the creation of operational control sheets, changing behavior and process parameters, changing certain equipment, and implementing autonomous maintenance plans. With the development of improvements and considering the main objective of the project to increase the production output of the line, it was possible to increase the output of one type of cylinders, although the same results were not achieved for the other type due to team changes during the project's implementation.
Increase of the output of a cork with rubber cylinder production line The competitiveness within the industry implies that companies must reinvent themselves. Competitive advantages are unstable, and therefore, companies need to strive daily to improve in order to be more efficient and productive. This report presents a project developed in a company responsible for the manufacture and processing of cork composites, in an area responsible for the agglomeration of cork cylinders with rubber. The growing demand for this type of product resulted in the need to significantly increase the production output. The methodology used was PDCA, focusing the first phase on analyzing the production process and recording the main failure modes and difficulties, through observation of production and informal interviews with operators. Lean techniques were used for organizing and prioritizing the recorded problems and also for the development of improvement actions. The major problems were related to the large number of corrective maintenance activities, which reduced the useful production time, and inefficient production practices and parameters. Taking into consideration the identified problems, improvement actions were developed, such as the creation of operational control sheets, changing behavior and process parameters, changing certain equipment, and implementing autonomous maintenance plans. With the development of improvements and considering the main objective of the project to increase the production output of the line, it was possible to increase the output of one type of cylinders, although the same results were not achieved for the other type due to team changes during the project's implementation.
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Keywords
Lean Output da produção Ações de melhoria Modos de falha Production output Improvement actions Failure modes