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Industrialização de um novo Projeto com Implementação de Melhoria Contínua em ambiente industrial
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| 7.98 MB | Adobe PDF |
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Advisor(s)
Abstract(s)
A dissertação enquadra-se no Mestrado de Engenharia Eletrotécnica e de
Computadores – Ramo de Sistemas e Planeamento Industrial do Instituto Superior de
Engenharia do Porto e foi realizada na Faurecia, um dos maiores fornecedores de
componentes na indústria automóvel, na fábrica FAA Moldados em São João da Madeira.
O documento aborda inicialmente o acompanhamento da industrialização de novos
projetos, através de uma ferramenta de planeamento avançado para prevenir modos de falha,
implementar alterações dos componentes e garantir que o produto satisfaz o cliente: o APQP
(Advanced Product Quality Planning). O objetivo proposto foi a digitalização e automatização
de processos e a implementação de VAVE (Value Added Value Engineering), no caso de estes
serem uma mais-valia para a empresa. Deste modo, foi aplicado um caso de estudo ambiente
industrial, que integra o desenvolvimento de VAVE na empresa com ideias de melhoria como:
redução de papel no processo de estendimento e corte; alteração da grease (massa
lubrificante) na produção de mecanismos e redução de pontos de cola em mecanismos. No
processo de redução de papel, a resolução para o problema identificado mostrou ser
complexa, dada a diversidade de opiniões da equipa de projeto e a integração de um software
específico para a solução. A alteração da grease ocorreu através da comparação da análise
dos consumos atuais em fábrica e preço do produto atual com a análise de propostas de
alteração. A análise destas teve em consideração as formulações das greases, a folha de dados
técnicos e os custos associados ao produto. Relativamente ao processo de redução de pontos
de cola, reconhecidos os problemas relacionados com HSE (Health, Safety and Environment)
na montagem dos mecanismos e a inexistência de valores standard nas fichas técnicas dos
produtos, foi utilizado o método “Tentativa e Erro” na procura da solução.
A metodologia As Is/To Be é apresentada como uma solução para a identificação
contínua de problemas e para potencial implementação das propostas de melhoria.
Com o desenvolvimento e implementação das ideias de melhoria no corte e na redução
dos pontos de cola, espera-se a eliminação de deslocamentos desnecessários e um saving
associado à otimização dos processos.
The dissertation is part of the Master's degree in Electrotechnical and Computer Engineering – Branch of Systems and Industrial Planning of the Instituto Superior de Engenharia do Porto and was held at Faurecia, one of the largest suppliers of components in the automotive industry, at the FAA Moldados factory in São João da Madeira. The document initially addresses the industrialization’s monitoring of new projects, through an advanced planning tool to prevent failure modes, implement component changes and ensure that the product satisfies the customer: Advanced Product Quality Planning (APQP). The proposal's goal was to digitalize and automate business processes and apply VAVE (Value Added Value Engineering), should these prove to be more advantageous to the company. The dissertation accompanies a case study in industrial environment, which integrates the development of VAVE in the company with improvement ideas such as: paper reduction in the process of cutting and estendimento; change of grease in the production of mechanisms and reduction of glue points in mechanisms. In the paper reduction process, the resolution to the identified problem proved to be complex, given the project’s team diversity of opinions and the integration of a specific software for the solution. The grease change occurred by comparing the analysis of the current consumption in the factory and the price of the current product with the analysis of the changing proposals. Their analysis considers grease formulations, technical data sheet and costs associated with the product. Regarding the process of reducing glue points, recognizing the problems related to HSE (Health, Safety and Environment) in the assembly of mechanisms and the lack of standard values in the technical data sheets of the products, the method "Tentativa e Erro" was used in the search for the solution. The Methodology As Is/To Be is presented as an answer to the ongoing problem identification and for a potential implementation of improvement proposals. With the development and implementation of ideas for improvement in cutting and reducing glue points, it is expected the elimination of unnecessary displacements and a saving associated with the optimization of processes. After the approval of the project and completion of the tests with the new grease, until the moment of submission of the viii dissertation, it remains to perform machine tests with the new grease and implementation of new metal plate.
The dissertation is part of the Master's degree in Electrotechnical and Computer Engineering – Branch of Systems and Industrial Planning of the Instituto Superior de Engenharia do Porto and was held at Faurecia, one of the largest suppliers of components in the automotive industry, at the FAA Moldados factory in São João da Madeira. The document initially addresses the industrialization’s monitoring of new projects, through an advanced planning tool to prevent failure modes, implement component changes and ensure that the product satisfies the customer: Advanced Product Quality Planning (APQP). The proposal's goal was to digitalize and automate business processes and apply VAVE (Value Added Value Engineering), should these prove to be more advantageous to the company. The dissertation accompanies a case study in industrial environment, which integrates the development of VAVE in the company with improvement ideas such as: paper reduction in the process of cutting and estendimento; change of grease in the production of mechanisms and reduction of glue points in mechanisms. In the paper reduction process, the resolution to the identified problem proved to be complex, given the project’s team diversity of opinions and the integration of a specific software for the solution. The grease change occurred by comparing the analysis of the current consumption in the factory and the price of the current product with the analysis of the changing proposals. Their analysis considers grease formulations, technical data sheet and costs associated with the product. Regarding the process of reducing glue points, recognizing the problems related to HSE (Health, Safety and Environment) in the assembly of mechanisms and the lack of standard values in the technical data sheets of the products, the method "Tentativa e Erro" was used in the search for the solution. The Methodology As Is/To Be is presented as an answer to the ongoing problem identification and for a potential implementation of improvement proposals. With the development and implementation of ideas for improvement in cutting and reducing glue points, it is expected the elimination of unnecessary displacements and a saving associated with the optimization of processes. After the approval of the project and completion of the tests with the new grease, until the moment of submission of the viii dissertation, it remains to perform machine tests with the new grease and implementation of new metal plate.
Description
Keywords
Melhoria contínua Otimização de processo Optimization Lean Metodologia As Is/ To be Saving Informatização de processos VAVE Industrialização de novos projetos Time study Method study Countinuous improvement