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Estudo de um layout de empresa: Análise de constrangimentos e propostas de melhoria
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| 5.53 MB | Adobe PDF |
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Abstract(s)
Esta dissertação foca-se na análise e otimização do layout da linha de produção da empresa Shamir Optical, com recurso ao software de simulação FlexSim. O objetivo principal foi desenvolver soluções para melhorar o desempenho da linha, com especial atenção para a zona identificada como bottleneck do processo produtivo. Para se cumprir com o objetivo do estudo, criou-se um modelo de simulação no FlexSim. Este modelo foi alimentado com dados recolhidos através de medições ao tempo de atividade dos operadores, e dados fornecidos pelos próprios equipamentos. Concluída a construção do modelo, e com vista a comprovar a fiabilidade dos resultados obtidos, procedeu-se à validação do modelo, através de comparações com dados reais, tendo-se obtido um erro relativamente baixo. Com base no modelo, foram criados seis cenários. As alterações realizadas incluíram reajustes na lógica de distribuição dos tabuleiros, aumento da capacidade do buffer, alteração da posição dos bloqueadores e tapetes de transporte, e ainda adição de um bloqueador à linha. Recorrendo a uma ferramenta do software FlexSim, o Experimenter, testaram-se os diferentes cenários para compreender quais apresentavam melhorias. Esta ferramenta torna este processo mais expedito, uma vez que permite a definição do número de simulações a realizar para cada cenário e a definição de diferentes inputs. Dos cenários testados, destacou-se o Cenário 5. Este caracteriza-se por apresentar um layout
que se assemelha a uma espinha de peixe, o que permite reduzir a distância e o tempo de transporte dos tabuleiros. Este cenário, quando comparado com o Cenário Modelo, apresentou melhorias ao nível do output semanal da Estação Combiners e da Estação Bloqueadores. Posteriormente adicionou-se um oitavo bloqueador à linha criada para o Cenário 5, tendo-se verificado um aumento ainda maior do output semanal de ambas as estações, apesar do output
médio por equipamento ter diminuído. Além da análise realizada ao output das estações de trabalho, foi também calculado o OEE de cada bloqueador. Com os resultados obtidos, verificou-se que os fatores Desempenho e
Qualidade se encontram muito abaixo dos valores de referência, pelo que foram sugeridas propostas de melhoria de forma a mitigar as limitações encontradas. Estas passam pela adoção do layout do Cenário 5 e pela revisão do plano de manutenções preventivas, de maneira a reduzir o número de paragens não planeadas relacionadas com falhas nos equipamentos. Espera-se que com a adoção destas propostas, se verifique um aumento da eficiência global da
linha de produção.
This dissertation focuses on the analysis and optimization of the production line layout at Shamir Optical, by using FlexSim simulation software. The main objective was to develop solutions to improve the line’s performance, with particular attention to the area identified as the bottleneck in the production process. To fulfill the objective, a simulation model was created in FlexSim. This model was loaded with data collected through measurements of operator’s activity time and data provided by the equipment. Once built, and to verify the reliability of the results obtained, the model was validated by comparing it with real data, resulting in a relatively low error rate. Based on the model, six scenarios were created. The changes made included adjustments to the distribution logic of the trays, increasing the buffer capacity, changing the blockers and conveyor belts positioning and adding a blocker to the line. Using a FlexSim tool called Experimenter, the different scenarios were tested to understand which ones improved performance. This tool speeds up the process, as it allows the definition of the number of simulations to be performed for each scenario, as well as different inputs. Out of the scenarios that were tested, Scenario 5 stood out. It features a layout that’s similar to a fishbone, which helps cut down on the distance and time it spends transporting the trays. When compared to the Model Scenario, it showed improvements in the weekly output of the Combiners Station and in the Blockers Station. Subsequently, an eight blocker was added to the line created for Scenario 5, resulting in an even greater increase in the weekly output of both stations, despite the decrease in the average output per equipment. In addition to analyzing the output of the workstations, the OEE of each blocker was calculated. The results showed that the Performance and Quality indicators were well below the reference values. For this reason, and to reduce the limitations found, some suggestions for improvement were made. These included adopting the layout from Scenario 5 and reviewing the preventive maintenance plan to reduce the number of unplanned stops related to equipment failures. It’s expected that adopting these measures will increase the overall efficiency of production line.
This dissertation focuses on the analysis and optimization of the production line layout at Shamir Optical, by using FlexSim simulation software. The main objective was to develop solutions to improve the line’s performance, with particular attention to the area identified as the bottleneck in the production process. To fulfill the objective, a simulation model was created in FlexSim. This model was loaded with data collected through measurements of operator’s activity time and data provided by the equipment. Once built, and to verify the reliability of the results obtained, the model was validated by comparing it with real data, resulting in a relatively low error rate. Based on the model, six scenarios were created. The changes made included adjustments to the distribution logic of the trays, increasing the buffer capacity, changing the blockers and conveyor belts positioning and adding a blocker to the line. Using a FlexSim tool called Experimenter, the different scenarios were tested to understand which ones improved performance. This tool speeds up the process, as it allows the definition of the number of simulations to be performed for each scenario, as well as different inputs. Out of the scenarios that were tested, Scenario 5 stood out. It features a layout that’s similar to a fishbone, which helps cut down on the distance and time it spends transporting the trays. When compared to the Model Scenario, it showed improvements in the weekly output of the Combiners Station and in the Blockers Station. Subsequently, an eight blocker was added to the line created for Scenario 5, resulting in an even greater increase in the weekly output of both stations, despite the decrease in the average output per equipment. In addition to analyzing the output of the workstations, the OEE of each blocker was calculated. The results showed that the Performance and Quality indicators were well below the reference values. For this reason, and to reduce the limitations found, some suggestions for improvement were made. These included adopting the layout from Scenario 5 and reviewing the preventive maintenance plan to reduce the number of unplanned stops related to equipment failures. It’s expected that adopting these measures will increase the overall efficiency of production line.
Description
Keywords
Discrete Event Simulation FlexSim Industrial Layout Bottleneck Simulação de eventos discretos