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Abstract(s)
Cada vez mais é exigido às empresas um elevado nível de qualidade e flexibilidade na produção. Para isto, e de forma a permanecer no mercado e se tornarem competitivas, os métodos de trabalho praticados devem ser fiáveis e eficientes.
O presente projeto procurou a melhoria na mudança de referência de um equipamento da indústria da cortiça, através da aplicação de métodos Lean.
O equipamento em estudo realiza a junção de uma rolha de cortiça a uma cápsula, sendo esta operação feita através da colagem com hot-melt. Como a variedade de produtos produzidos é enorme, isto leva a que os changeover sejam realizados com bastante frequência.
O método seguido neste projeto foi o estudo e recolha de informação sobre a filosofia Lean de produção e a sua aplicação na indústria da cortiça. Também se analisou as condições de trabalho da máquina de capsular, e quais as oportunidades de melhoria possíveis. Para isto, foi elaborado o VSM (Value Stream Mapping), de forma a perceber quais são as operações que realmente acrescentam valor ao produto.
Foram ainda implementados os 6S, com o objetivo de sensibilizar os operadores para os benefícios resultantes da organização e limpeza do local de trabalho e das ferramentas.
A metodologia SMED (Single Minute of Exchange of Die), foi aplicada de forma a reduzir o tempo de paragem provocado por mudanças de ferramenta, sendo que foi obtida uma redução de 43% no tempo total de changeover. Para monitorizar todo o desenvolvimento do projeto SMED, foi ainda criado um modelo A3.
Por fim, foi implementado o cálculo do OEE (Overall Equipment Effectiveness), como indicador da eficiência geral do equipamento, e de forma a melhorar a monitorização de possíveis desvios que possam ocorrer durante a produção.
Os resultados obtidos comprovam ainda, que as ferramentas lean são um método poderoso para obter resultados sem a necessidade de grandes investimentos.
Organizations are increasingly required to have a high level of quality and flexibility in production. In order to remain in the market and become competitive, the working methods practised must be reliable and efficient. The present project sought the improvement in the reference change of an equipment used in cork industry, through the application of Lean methods. The equipment under study performs the union of a cork stopper to a capsule, which is done by glueing it with hot-melt glue. Since the variety of products produced is huge, this almost makes the changeover activity a frequency. The method followed in this work was the study and collection of information on the Lean production philosophy and its application in the cork industry. The working conditions of the assembly machine were also analyzed, searching for improvement opportunities. Thus, it was elaborated the Value Stream Mapping (VSM) in order to perceive which are the operations that really add value to the product. The SMED (Single Minute of Exchange of Die) methodology was applied in a way to reduce the downtime caused by tool changes, and a reduction of 43% in total changeover time was obtained. To monitor the entire development of the SMED project, it was also created an A3 model. Finally, the OEE (Overall Equipment Efficiency) calculation was implemented as an indicator of overall equipment efficiency, in order to improve the monitoring of possible deviations during production. The results obtained also prove that lean tools are a powerful method to obtain results without the need for large investments.
Organizations are increasingly required to have a high level of quality and flexibility in production. In order to remain in the market and become competitive, the working methods practised must be reliable and efficient. The present project sought the improvement in the reference change of an equipment used in cork industry, through the application of Lean methods. The equipment under study performs the union of a cork stopper to a capsule, which is done by glueing it with hot-melt glue. Since the variety of products produced is huge, this almost makes the changeover activity a frequency. The method followed in this work was the study and collection of information on the Lean production philosophy and its application in the cork industry. The working conditions of the assembly machine were also analyzed, searching for improvement opportunities. Thus, it was elaborated the Value Stream Mapping (VSM) in order to perceive which are the operations that really add value to the product. The SMED (Single Minute of Exchange of Die) methodology was applied in a way to reduce the downtime caused by tool changes, and a reduction of 43% in total changeover time was obtained. To monitor the entire development of the SMED project, it was also created an A3 model. Finally, the OEE (Overall Equipment Efficiency) calculation was implemented as an indicator of overall equipment efficiency, in order to improve the monitoring of possible deviations during production. The results obtained also prove that lean tools are a powerful method to obtain results without the need for large investments.
Description
Keywords
Cortiça Rolhas Capsuladas Lean 6S Redução de Desperdício Metodologia A3 VSM SMED OEE Cork Bartop Corks Waste Reduction A3 Methodology