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Abstract(s)
O TPM - Total Productive Maintenance visa melhorar os processos de manutenção e estabelecer uma ligação com a produção, com o objetivo de melhorar a qualidade do produto, reduzir os desperdícios, reduzir os custos de produção, aumentar a disponibilidade dos equipamentos e melhorar o estado da organização no âmbito da manutenção. Este projeto foi realizado num contexto industrial, numa empresa vocacionada para a produção e distribuição de tintas, a CIN - Corporação Industrial do Norte, com o objetivo de reduzir perdas e melhorar a produtividade dos equipamentos, através da implementação do TPM. Dentro desta metodologia, deu-se maior foco aos pilares da manutenção autónoma, da manutenção planeada e ao treino e formação. Também no âmbito deste relatório adotou-se uma metodologia de investigação que se enquadra nos princípios de Action-Research, utilizando ferramentas da qualidade. Numa primeira fase do trabalho, realizou-se uma análise sobre as causas de avarias mais comuns nos equipamentos. Este estudo resultou na criação de Check-list de deteção de avarias nos equipamentos por parte do operador. Numa segunda fase, procedeu-se à criação de planos de manutenção autónoma. Durante este processo, foram criados ficheiros de procedimento operacional, de forma a padronizar e facilitar as intervenções de manutenção. Foi sempre um princípio basilar incentivar a procura sistemática de metodologias de trabalho mais eficazes no sentido de otimizar a relação custos/produtividade. Nesse sentido, e no caso concreto desta empresa, após observação cuidada de todo o processo associado à implementação da metodologia TPM, em articulação com os departamentos e consequente reflexão, foi possível constatar um aumento da disponibilidade dos equipamentos. É de salientar que, a disponibilidade da máquina de enchimento 1 aumentou 14% face ao ano anterior, assim como, ocorreu uma diminuição de 13% do tempo de paragem do equipamento para intervenção da manutenção, no mesmo período homólogo. A eficácia global do equipamento (OEE), das máquinas de enchimento, aumentou em média 5%. Estima-se uma redução dos custos anuais de 5.550,40€ em mão de obra e 10.778,40€ com subcontratação. Assim, obtevese uma reestruturação multifacetada da manutenção, a qual se refletiu na melhoria do serviço prestado e na garantia de maiores níveis de disponibilidade dos equipamentos, assegurando o cumprimento de prazos e boa imagem da organização.
TPM - Total Productive Maintenance aims to optimize the maintenance of processes and establish a connection with the production in order to improve the quality of the product, reduce the waste and the costs of the production itself, increase the equipment availability and overall improve the state of maintenance organization. This report was written in an industrial context, more precisely in a paint industry whose business lies in the production and distribution of paints, “CIN - Corporação Industrial do Norte”, and its objective is to reduce losses and increase equipment productivity through TPM implementation. Within this methodology, a greater focus was given to the pillars of autonomous and planned maintenance, training and formation. Within the scope of this report, a research methodology was adopted, that fits the principles of Action-Research, using quality tools. The first phase of the work was a field survey on the most common malfunctions in the equipment. The result of this research was the creation of a check-list of equipment malfunctions detected by the operator. The next step was creating plans of autonomous maintenance. During this process, files of operational procedures were made to standardize and facilitate the maintenance interventions. In addition, the equipment was labelled, so that it would be much easier to identify the intervention sites. It has always been a basic principle to encourage the systematic search for more effective working methodologies to optimise the cost/productivity relationships (ratio). In this sense, and in the concrete case of this company, after a careful surveillance of the entire process associated with the implementation of the TPM methodology, in combination with the departments and consequent reflection, it was possible to observe a reduction in the number of hours of equipment stoppage, which was reflected on the increase in its availability. It should be noted that the availability of the filling machine 1 increased by 14% compared to the previous year, as well as a 13% decrease in the stopping time of the equipment for maintenance intervention in the same homologous period. The overall effectiveness of the equipment (OEE) of filling machines increased on average about 5%. Thus, it is estimated a reduction in annual costs of 5,550.40€ in labor and 10,778.40€ with subcontracting. Therefore, a multifaceted restructuring of maintenance was obtained, which was reflected on the improvement of the service provided and on the guarantee of higher levels of equipment availability, ensuring compliance with deadlines and good image of the organization.
TPM - Total Productive Maintenance aims to optimize the maintenance of processes and establish a connection with the production in order to improve the quality of the product, reduce the waste and the costs of the production itself, increase the equipment availability and overall improve the state of maintenance organization. This report was written in an industrial context, more precisely in a paint industry whose business lies in the production and distribution of paints, “CIN - Corporação Industrial do Norte”, and its objective is to reduce losses and increase equipment productivity through TPM implementation. Within this methodology, a greater focus was given to the pillars of autonomous and planned maintenance, training and formation. Within the scope of this report, a research methodology was adopted, that fits the principles of Action-Research, using quality tools. The first phase of the work was a field survey on the most common malfunctions in the equipment. The result of this research was the creation of a check-list of equipment malfunctions detected by the operator. The next step was creating plans of autonomous maintenance. During this process, files of operational procedures were made to standardize and facilitate the maintenance interventions. In addition, the equipment was labelled, so that it would be much easier to identify the intervention sites. It has always been a basic principle to encourage the systematic search for more effective working methodologies to optimise the cost/productivity relationships (ratio). In this sense, and in the concrete case of this company, after a careful surveillance of the entire process associated with the implementation of the TPM methodology, in combination with the departments and consequent reflection, it was possible to observe a reduction in the number of hours of equipment stoppage, which was reflected on the increase in its availability. It should be noted that the availability of the filling machine 1 increased by 14% compared to the previous year, as well as a 13% decrease in the stopping time of the equipment for maintenance intervention in the same homologous period. The overall effectiveness of the equipment (OEE) of filling machines increased on average about 5%. Thus, it is estimated a reduction in annual costs of 5,550.40€ in labor and 10,778.40€ with subcontracting. Therefore, a multifaceted restructuring of maintenance was obtained, which was reflected on the improvement of the service provided and on the guarantee of higher levels of equipment availability, ensuring compliance with deadlines and good image of the organization.
Description
Keywords
Manutenção Manutenção Autónoma Melhoria Continua Manutenção Preventiva TPM Maintenance Autonomous Maintenance Continuous Improvement Preventive Maintenance