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Abstract(s)
A produção de pneus, tal como a de outro tipo de componentes automóveis, necessita de respeitar os principais pilares da indústria automóvel: elevada competitividade e qualidade, com tempos de entrega dentro do que é requerido pelas linhas finais de montagem. Existem alguns produtores de pneus a nível global, e a competição entre eles é muito elevada. A isto, acresce o facto de que a qualidade deste tipo de produto é crucial, por razões de segurança. Assim, este tipo de sistemas produtivos necessita de produzir produtos de elevada qualidade em curtos períodos de tempo, reduzindo permanentemente os seus custos associados. Tendo em conta que o preço e quantidade da matéria-prima para cada pneu permanece aproximadamente inalterado, os processos utilizados na sua produção assumem um papel muito importante.
O presente trabalho foi desenvolvido em ambiente industrial, na empresa Continental Mabor, respondendo à necessidade de análise do seu processo de extrusão. Este produzia uma grande quantidade de material não conforme, influenciando diretamente um dos seus indicadores de desempenho, designado por geração de work-off. Assim, o objetivo a atingir seria a redução deste desperdício, através da análise da presente situação e pelo desenvolvimento de sugestões de melhoria. A metodologia aplicada a este problema foi a Seis Sigma, utilizando a abordagem para melhoria da qualidade de produtos existentes: DMAIC (Define, Measure, Analyse, Improve and Control). Ao longo das diferentes etapas, o processo foi mapeado em detalhe, utilizando ferramentas da qualidade de forma estruturada, para uma resolução eficiente do problema. Conclui-se que o trabalho foi finalizado com sucesso, uma vez que após a implementação das sugestões de melhoria, a geração de material não conforme foi acentuadamente reduzida. Como consequência, os custos relacionados com não-conformidades foram também reduzidos.
Tire manufacturing as well as other automotive components, need to respect the main pillars of the automotive industry: high competitiveness and quality with delivery time within the standards required by the final assembly lines. There are some importante tire producers playing worldwide and the competition among them is very high. Furthermore, the quality of this type of product is crucial due to safety reasons. Thus, tire manufacturers need to produce high quality products in a short period, reducing permanently the costs associated to the product. Attending that raw material cost and quantity almost remains the same for each type of tire, the processes used in their production assume a very important role. The work was developed in industrial environment at Continental Mabor, answering to the need for analysis of the extrusion process. The production of a high quantity of nonconforming material directly affected one of the factory key performance indicators, named as work-off generation. Therefore, the goal to achieve would be the reduction of this waste generation through the current situation analysis and the development of improvement suggestions. The used methodology was the Six Sigma, applying the quality improvement approach for existing products: DMAIC. Going through the different stages, the process was mapped in detail using the quality tools in a structured way to achieve an efficient problem resolution. It can be concluded that this work was successfully finished since, after the implementation of proposed improvements, the generation of nonconforming material drastically decreased. As result, the costs relatively to non-conformities were also reduced.
Tire manufacturing as well as other automotive components, need to respect the main pillars of the automotive industry: high competitiveness and quality with delivery time within the standards required by the final assembly lines. There are some importante tire producers playing worldwide and the competition among them is very high. Furthermore, the quality of this type of product is crucial due to safety reasons. Thus, tire manufacturers need to produce high quality products in a short period, reducing permanently the costs associated to the product. Attending that raw material cost and quantity almost remains the same for each type of tire, the processes used in their production assume a very important role. The work was developed in industrial environment at Continental Mabor, answering to the need for analysis of the extrusion process. The production of a high quantity of nonconforming material directly affected one of the factory key performance indicators, named as work-off generation. Therefore, the goal to achieve would be the reduction of this waste generation through the current situation analysis and the development of improvement suggestions. The used methodology was the Six Sigma, applying the quality improvement approach for existing products: DMAIC. Going through the different stages, the process was mapped in detail using the quality tools in a structured way to achieve an efficient problem resolution. It can be concluded that this work was successfully finished since, after the implementation of proposed improvements, the generation of nonconforming material drastically decreased. As result, the costs relatively to non-conformities were also reduced.
Description
Keywords
Produção de pneus Melhoria de produtividade Melhoria de qualidade Automação Seis Sigma DMAIC Tires production Increasing productivity Quality improvement Automation Six Sigma