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Authors
Abstract(s)
Com o aumento das exigências do mercado, as empresas precisam reagir de forma
rápida e eficiente para corresponder à demanda dos clientes. Porém, mesmo as mais
modernas estruturas e tecnologias, não são suficientes para atrair o consumidor. Dessa
forma, o objetivo estratégico se concentra em reduzir os desperdícios e ultrapassar os
obstáculos por meio da aplicação de métodos que interferem diretamente no aumento
da capacidade disponível, da produtividade diária das linhas e da eficiência das
máquinas e dos operadores.
Em específico, o seguinte estudo teve como finalidade a análise e otimização do
processo de uma linha de produção que fabrica componentes para os sistemas de ar
condicionado, nomeada AA6, por meio da aplicação de ferramentas de melhoria para
aprimorar o funcionamento geral do sistema. Com base na filosofia Lean, a intenção foi
analisar o volume de produção e a capacidade produtiva ligado à produtividade. Por
meio dessa metodologia, foi exequível identificar os pontos críticos que precisavam ser
aperfeiçoados e aplicar métodos para enfatizar a otimização, como o Standard Work
para padronização das operações e o Kaizen na melhoria contínua dos processos.
Após a execução do estudo pode-se concluir que diversas foram as oportunidades de
melhorias identificadas que representaram um aumento de 10% na Eficiência Geral do
Equipamento (OEE), passando de 72% na 1ª análise para 82% após a implementação das
otimizações estabelecidas. Todas essas soluções, por sua vez propiciaram o ajuste dos
objetivos de produção, da capacidade produtiva, da eficiciência e principalmente da
evolução do processo produtivo da linha AA6 durante esta análise.
Com a aplicação das melhorias em cada posto de trabalho, foi possível comparar a
redução dos tempos de ciclos, deslocamentos excessivos, movimentações
desnecessárias, as não conformidades com os postos de trabalho, problemas de
máquina, aceleração do processo e adequação das referências em cada família de
produtos, com vista a otimizar o processo. Isso tende a aumentar a probabilidade de
cumprimentos das demandas com o cliente e ocasiona satisfação e fidelidade dos
consumidores.
Due to the increase in market requirements, companies must respond more rapidly and efficiently in order to meet customer demand. However, even the most modern facilities and technologies have fallen short of attracting the consumer. The strategic objective has thus focused on reducing waste and overcome obstacles through the application of methods which directly impact on the increase of available capacity and daily production on lines, as well as that of machine and operator efficiency. More specifically, the purpose of the study at hand was to analyze and optimize the process of air-conditioner line AA6 by means of the implementation of improvement tools to enhance the system’s general performance. Drawing on Lean philosophy, the intention was to analyze the volume and capacity of production associated to manufacturing productivity. Through this methodology, one was able to identify the critical points requiring improvement and then proceeded with the implementation of methods to enhance optimization, such as the use of Standard Work to standardize operations, and Kaizen to ensure the continuous improvement of the processes. After executing the study, one was able to conclude that the identification of various opportunities for improvement represented an increase of 10% in Overall Equipment Effectiveness (OEE), from 72% obtained in the first analysis to 82% after the implementation of established optimization procedures. All of these solutions then enabled one to adjust the objectives related to production, productive capacity, efficiency and, above all, the enhancement of the production process on line AA6 during this specific analysis. Due to the implementation of improvements at each work station, one was able to optimize the process by comparing the reduction in cycle times, excessive displacements, unnecessary movements, non-conformities with workstations, machine problems, process speeds and the suitable adjustment of references for each product group. This approach will tend towards increasing the probability of meeting customer demands which will, in turn, lead to customer satisfaction and loyalty.
Due to the increase in market requirements, companies must respond more rapidly and efficiently in order to meet customer demand. However, even the most modern facilities and technologies have fallen short of attracting the consumer. The strategic objective has thus focused on reducing waste and overcome obstacles through the application of methods which directly impact on the increase of available capacity and daily production on lines, as well as that of machine and operator efficiency. More specifically, the purpose of the study at hand was to analyze and optimize the process of air-conditioner line AA6 by means of the implementation of improvement tools to enhance the system’s general performance. Drawing on Lean philosophy, the intention was to analyze the volume and capacity of production associated to manufacturing productivity. Through this methodology, one was able to identify the critical points requiring improvement and then proceeded with the implementation of methods to enhance optimization, such as the use of Standard Work to standardize operations, and Kaizen to ensure the continuous improvement of the processes. After executing the study, one was able to conclude that the identification of various opportunities for improvement represented an increase of 10% in Overall Equipment Effectiveness (OEE), from 72% obtained in the first analysis to 82% after the implementation of established optimization procedures. All of these solutions then enabled one to adjust the objectives related to production, productive capacity, efficiency and, above all, the enhancement of the production process on line AA6 during this specific analysis. Due to the implementation of improvements at each work station, one was able to optimize the process by comparing the reduction in cycle times, excessive displacements, unnecessary movements, non-conformities with workstations, machine problems, process speeds and the suitable adjustment of references for each product group. This approach will tend towards increasing the probability of meeting customer demands which will, in turn, lead to customer satisfaction and loyalty.
Description
Keywords
Setor Automóvel Lean Manufacturing Capacidade Produtiva Otimização da Produção Desperdício Automotive Sector Lean Thinking Productive Capacity Production Optimization Waste