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Advisor(s)
Abstract(s)
Num mercado globalizado, a procura contínua de vantagens competitivas é um fator crucial para o sucesso das organizações. A melhoria contínua dos processos é uma abordagem usual, uma vez que os resultados destas melhorias vão se traduzir diretamente na qualidade dos produtos.
Neste contexto, a metodologia Failure Mode Effect Analysis (FMEA) é muito utilizada, especialmente pelas suas características proactivas, que permitem a identificação e a prevenção de erros do processo. Assim, quanto mais eficaz for a aplicação desta ferramenta, mais benefícios terá a organização. Assim, quando é utilizado com eficácia, o FMEA de Processo, além de ser um método poderoso na análise do processo, permite a melhoria contínua e a redução dos custos [1] .
Este trabalho de dissertação teve como objetivo avaliar a eficácia da utilização da ferramenta do FMEA de processo numa organização certificada segundo a norma ISO/TS16949. A metodologia proposta passa pela análise de dados reais, ou seja, comparar as falhas verificadas no mercado com as falhas que tinham sido identificadas no FMEA.
Assim, ao analisar o nível de falhas identificadas e não identificadas durante o FMEA e a projeção dessas falhas no mercado, consegue-se determinar se o FMEA foi mais ou menos eficaz, e ainda, identificar fatores que condicionam a melhor utilização da mesma.
Este estudo, está organizado em três fases, a primeira apresenta a metodologia proposta , com a definição de um fluxograma do processo de avaliação e as métricas usadas, a segunda fase a aplicação do modelo proposto a dois casos de estudo, e uma última fase, que consiste na análise comparativa, individual e global, que visa, além de comparar esultados, identificar pontos fracos durante a execução do FMEA.
Os resultados do caso de estudo indicam que a ferramenta do FMEA tem sido usada com eficácia, pois consegue-se identificar uma quantidade significativa de falhas potenciais e evitá-las. No entanto, existem ainda falhas que não foram identificadas no FMEA e que apareceram no cliente, e ainda, algumas falhas que foram identificadas e apareceram no cliente. As falhas traduzem-se em má qualidade e custos para o negócio, pelo que são propostas ações de melhoria. Pode-se concluir que uma boa utilização do FMEA pode ser um fator importante para a qualidade do serviço ao cliente, e ainda, com impacto dos custos.
Nowadays, in a globalized market, the continuous search for competitive advantages is a crucial factor for the success of organizations. The continuous improvement of processes is a usual approach, since the result of these improvements will influence directly the product quality. In this context, the Failure Mode Effect Analysis (FMEA) methodology is widely used, especially due to its proactive characteristics, which enable the identification and prevention of process errors. Thus, the more effectively this tool is applied, the more benefits it will bring to the organization. Thus, when it is used efficiently, the Process FMEA, besides being a powerful method in process analysis, also enables continuous improvement and cost reduction [1]. This thesis had therefore the aim of evaluating the effectiveness of the use of the process FMEA tool in a certified organization according to ISO/TS16949. The proposed methodology involves the analysis of real data, i.e. compare the failures found in the market with the failures that had been identified in the FMEA. Thus, when analyzing the level of failures identified and not identified during the FMEA and the projection of these failures in the market, we can determine whether the FMEA was more or less effective, and also identify factors that condition the best use of it. This study is organized into three phases: the first presents the proposed methodology, with the definition of a flowchart of the evaluation process and the used metrics, the second phase the implementation of the proposed model to two case studies, and a final stage, which consists of the individual, comparative and global analysis, which aims, besides comparing results, to identify the weaknesses during the FMEA execution. The results of the case study indicate that the FMEA tool has been used effectively, because it is possible to identify a significant amount of potential failures and avoid them. However, there are still failures that have not been identified in the FMEA and appeared at the customer, and also failures that have been identified and appeared at the customer. The failures result in poor quality and costs for the business, so that improvement actions are proposed. We can conclude that a good application of FMEA can be an important fator for customer service quality, and also has an impact on costs.
Nowadays, in a globalized market, the continuous search for competitive advantages is a crucial factor for the success of organizations. The continuous improvement of processes is a usual approach, since the result of these improvements will influence directly the product quality. In this context, the Failure Mode Effect Analysis (FMEA) methodology is widely used, especially due to its proactive characteristics, which enable the identification and prevention of process errors. Thus, the more effectively this tool is applied, the more benefits it will bring to the organization. Thus, when it is used efficiently, the Process FMEA, besides being a powerful method in process analysis, also enables continuous improvement and cost reduction [1]. This thesis had therefore the aim of evaluating the effectiveness of the use of the process FMEA tool in a certified organization according to ISO/TS16949. The proposed methodology involves the analysis of real data, i.e. compare the failures found in the market with the failures that had been identified in the FMEA. Thus, when analyzing the level of failures identified and not identified during the FMEA and the projection of these failures in the market, we can determine whether the FMEA was more or less effective, and also identify factors that condition the best use of it. This study is organized into three phases: the first presents the proposed methodology, with the definition of a flowchart of the evaluation process and the used metrics, the second phase the implementation of the proposed model to two case studies, and a final stage, which consists of the individual, comparative and global analysis, which aims, besides comparing results, to identify the weaknesses during the FMEA execution. The results of the case study indicate that the FMEA tool has been used effectively, because it is possible to identify a significant amount of potential failures and avoid them. However, there are still failures that have not been identified in the FMEA and appeared at the customer, and also failures that have been identified and appeared at the customer. The failures result in poor quality and costs for the business, so that improvement actions are proposed. We can conclude that a good application of FMEA can be an important fator for customer service quality, and also has an impact on costs.
Description
Keywords
Eficácia do FMEA Qualidade Custos Effectiveness of FMEA Quality improvement Costs reduction