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Advisor(s)
Abstract(s)
Se antigamente as empresas tinham um bom posicionamento no mercado devido exclusivamente ao seu produto, hoje em dia, isso não é suficiente, uma vez que vivemos num mundo apelidado de “mundo VUCA” (Volatility, Uncertainty, Complexity ,Ambiguity), onde a incerteza, a volatilidade, a complexidade e ambiguidade tornaram-se palavras chave do nosso dia a dia. Para se ter sucesso é exigida, uma grande capacidade de adaptação às mudanças, resiliência para ultrapassar as dificuldades, e criatividade para a criação de novas soluções. E como dizia Darwin: “Não sobrevive a espécie mais forte, mas a que se adapta à mudança” A presente dissertação acompanha um caso de estudo em ambiente industrial na Bosch de Ovar, associado à produção de um tipo de câmaras de vídeo vigilância. A câmara estudada já se encontrava no mercado quando foi transferida para a fábrica de Ovar, e contava com altos volumes de produção, o que obrigou a equipa tivesse que rapidamente criar as condições necessárias para que o produto fosse produzido em Ovar o mais rapidamente possível, com o nível de qualidade exigido e ao menor custo. No início o desafio mostrava-se complexo, devido à rapidez com que todas as decisões foram tomadas e pela falta de conhecimento maduro do produto. Viveram-se tempos de incerteza e ambiguidade devido à pandemia instalada de Covid 19. As condições adversas fizeram a equipa ser criativa, ambiciosa e mais do que nunca, ágil. Ao longo do documento serão apresentadas metodologias usadas na industrialização de novos produtos, como o DFMA (Design For Manufacturing Assembly), e a PFMEA (Process Failure Mode and Effect Analysis), é descrito de que modo essas metodologias foram associadas a um projeto que já tinha sido industrializado. A melhoria contínua, teve um papel muito importante na realização deste projeto, uma vez que foi através de algumas das suas metodologias como, value stream mapping, lean line design, relatório A3, 5S, ciclo PDCA, identificação de desperdícios, que foi possível melhorar iterativamente o processo. A cada iteração foi realizado um estudo de tempos e métodos e gráficos de balanceamento. Foram ainda realizadas análises ergonómicas aos postos de trabalho dos operadores, garantindo que tinham as condições indicadas para trabalhar, sem prejudicar a sua saúde. E por fim foi proposto e validado um novo layout. No final todo o trabalho realizado, permitiu uma poupança tangível, superior a meio milhão de euros. Como resultados intangíveis, será possível verificar a redução de 16 m2 de chão de fábrica, a atualização da PFMEA com a redução de vários RPN (Risk Priority Number), a revisão do DFMA, a diminuição das falhas de CAT (Costumer Acceptance Test), o aumento de capacidade instalada e ainda a melhoria nas condições de acondicionamento de matérias primas.
If in the past companies had a good position in the market due exclusively to their product today, but this is not enough, since we live in a VUCA (Volatility, Uncertainty, Complexity and Ambiguity) world and where these words become part of our lives. To be successful it is necessary to have a great capacity to adapt to any changes that may occur such as: resilience to overcome difficulties, and creativity to create new solutions. As Darwin said: “It is not the strongest of the species that survives, it is the one that is the most adaptable to change”. This dissertation encompasses a case study in an industrial environment at Bosch from Ovar, associated with the production of a type of video surveillance cameras. The studied camera was already on the market when it was transferred to the Ovar factory, and had high production volumes, which forced the team to quickly create the necessary conditions for the product to be produced in Ovar, as soon as possible, with the required level of quality and at the lowest cost. At the beginning, the challenge proved to be complex due to the speed with which all decisions were made and the lack of knowledge the product. Times of uncertainty have been experienced due to the pandemic installed in Covid 19. The adverse conditions made the team creative, ambitious and more than ever agile. The document will present methodologies used in the industrialization of new products, such as DFMA (Design For Manufacturing Assembly), and PFMEA (Process Failure Mode and Effect Analysis), describing how these methodologies were associated with a project that had already been industrialized. Continuous improvement played a very important role in the realization of this project, since it was through some of its methodologies such as, value stream mapping, lean line design, A3 report, 5S, PDCA cycle, waste identification, that it was possible to improve iteratively the process. At each iteration, a study of times and methods and balancing graphs was carried out. Ergonomic analyzes were also carried out on the operator’s workstations, ensuring that they had the right conditions to work, without harming their health. Finally, a new layout was proposed and validated. In the end, all the work carried out allowed for tangible savings of over half a million euros. As intangible results, it will be possible to verify the reduction of 16 !!of the factory floor, the update of the PFMEA with the reduction of several RPN (Risk Priority Number), the revision of the DFMA, the reduction of CAT (Costumer Acceptance Test), failures, the increase in installed capacity and also the improvement in conditions for packaging raw materials.
If in the past companies had a good position in the market due exclusively to their product today, but this is not enough, since we live in a VUCA (Volatility, Uncertainty, Complexity and Ambiguity) world and where these words become part of our lives. To be successful it is necessary to have a great capacity to adapt to any changes that may occur such as: resilience to overcome difficulties, and creativity to create new solutions. As Darwin said: “It is not the strongest of the species that survives, it is the one that is the most adaptable to change”. This dissertation encompasses a case study in an industrial environment at Bosch from Ovar, associated with the production of a type of video surveillance cameras. The studied camera was already on the market when it was transferred to the Ovar factory, and had high production volumes, which forced the team to quickly create the necessary conditions for the product to be produced in Ovar, as soon as possible, with the required level of quality and at the lowest cost. At the beginning, the challenge proved to be complex due to the speed with which all decisions were made and the lack of knowledge the product. Times of uncertainty have been experienced due to the pandemic installed in Covid 19. The adverse conditions made the team creative, ambitious and more than ever agile. The document will present methodologies used in the industrialization of new products, such as DFMA (Design For Manufacturing Assembly), and PFMEA (Process Failure Mode and Effect Analysis), describing how these methodologies were associated with a project that had already been industrialized. Continuous improvement played a very important role in the realization of this project, since it was through some of its methodologies such as, value stream mapping, lean line design, A3 report, 5S, PDCA cycle, waste identification, that it was possible to improve iteratively the process. At each iteration, a study of times and methods and balancing graphs was carried out. Ergonomic analyzes were also carried out on the operator’s workstations, ensuring that they had the right conditions to work, without harming their health. Finally, a new layout was proposed and validated. In the end, all the work carried out allowed for tangible savings of over half a million euros. As intangible results, it will be possible to verify the reduction of 16 !!of the factory floor, the update of the PFMEA with the reduction of several RPN (Risk Priority Number), the revision of the DFMA, the reduction of CAT (Costumer Acceptance Test), failures, the increase in installed capacity and also the improvement in conditions for packaging raw materials.
Description
Keywords
Lean Ergonomia Estudo de tempos de métodos Value Stream Mapping Lean Line Design FMEA Ergonomics Study of times and method