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Melhoria e otimização da gestão da manutenção preventiva numa empresa de cartão canelado
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A presente dissertação insere-se no contexto da melhoria contínua dos processos industriais,
com abordagem na gestão da manutenção preventiva e na fiabilidade operacional de ativos
críticos. O projeto foi desenvolvido na unidade Celpack da empresa Smurfit Westrock, dedicada
à produção de embalagens em cartão canelado, tendo como principal objetivo aumentar a
eficiência e reduzir o número de falhas da máquina DRO 1628 NT, um dos equipamentos com
maior impacto na unidade em termos de volume de produção e criticidade operacional.
Para tal, foi adotada uma abordagem de Investigação-Ação, que possibilitou a identificação de
problemas no terreno e a implementação participada de soluções. O trabalho teve início com
uma análise de criticidade de ativos, que fundamentou a escolha da máquina-alvo.
Seguidamente, foi delineada uma estratégia de manutenção baseada no programa corporativo
Fundamentals, incluindo a criação de manuais de manutenção autónoma, folhas de verificação
padronizadas e a organização do posto de trabalho segundo a metodologia 5S. Em
complemento, foi desenvolvida uma aplicação no PowerApp para digitalização e rastreabilidade
dos pedidos de manutenção, melhorando substancialmente a comunicação entre produção e
equipa técnica.
A avaliação dos resultados foi efetuada com base na comparação de indicadores operacionais
entre setembro de 2024 e maio de 2025, nomeadamente produtividade, produção total, MTBF,
MTTR e número de pedidos de intervenção. Os dados revelam melhorias significativas, com
destaque para o aumento da produtividade, a duplicação do tempo médio entre falhas e a
redução acentuada do tempo médio de reparação. Estes ganhos traduziram-se também em
maior responsabilização dos operadores, melhoria do ambiente de trabalho e aumento da
eficiência na gestão das atividades de manutenção.
Os resultados obtidos comprovam a eficácia das ferramentas implementadas e evidenciam o
potencial de replicação desta abordagem noutras máquinas e unidades, contribuindo para a
construção de um sistema de manutenção mais autónomo, visual e digitalmente integrado.
This dissertation is set within the context of continuous improvement of industrial processes, with a focus on preventive maintenance management and the operational reliability of critical assets. The project was carried out at the Celpack unit of Smurfit Westrock, a company dedicated to the production of corrugated cardboard packaging, and its main objective was to increase efficiency and reduce the number of failures of the DRO 1628 NT machine—one of the most impactful assets in terms of production volume and operational relevance. An Action Research approach was adopted, allowing for on-site problem identification and collaborative implementation of solutions. The project began with a criticality analysis of the main production assets, which supported the selection of the target equipment. A maintenance strategy was then defined and applied, based on the company’s Fundamentals program, involving the creation of autonomous maintenance manuals, standardized inspection sheets, and the organization of the workstation using the 5S methodology. Additionally, a PowerApps digital application was developed to improve maintenance request traceability and streamline communication between production and the technical team. Project outcomes were evaluated through a comparative analysis of operational indicators between September 2024 and May 2025, including productivity, total production, MTBF, MTTR, and the number of maintenance requests. The results show significant improvements, notably the increase in productivity, doubling of the mean time between failures, and a substantial reduction in meantime to repair. These improvements also contributed to enhanced operator accountability, a better work environment, and greater efficiency in maintenance task management. The results confirm the effectiveness of the implemented tools and highlight the potential for replicating this approach to other machines and industrial units, supporting the development of a more autonomous, visual, and digitally integrated maintenance system.
This dissertation is set within the context of continuous improvement of industrial processes, with a focus on preventive maintenance management and the operational reliability of critical assets. The project was carried out at the Celpack unit of Smurfit Westrock, a company dedicated to the production of corrugated cardboard packaging, and its main objective was to increase efficiency and reduce the number of failures of the DRO 1628 NT machine—one of the most impactful assets in terms of production volume and operational relevance. An Action Research approach was adopted, allowing for on-site problem identification and collaborative implementation of solutions. The project began with a criticality analysis of the main production assets, which supported the selection of the target equipment. A maintenance strategy was then defined and applied, based on the company’s Fundamentals program, involving the creation of autonomous maintenance manuals, standardized inspection sheets, and the organization of the workstation using the 5S methodology. Additionally, a PowerApps digital application was developed to improve maintenance request traceability and streamline communication between production and the technical team. Project outcomes were evaluated through a comparative analysis of operational indicators between September 2024 and May 2025, including productivity, total production, MTBF, MTTR, and the number of maintenance requests. The results show significant improvements, notably the increase in productivity, doubling of the mean time between failures, and a substantial reduction in meantime to repair. These improvements also contributed to enhanced operator accountability, a better work environment, and greater efficiency in maintenance task management. The results confirm the effectiveness of the implemented tools and highlight the potential for replicating this approach to other machines and industrial units, supporting the development of a more autonomous, visual, and digitally integrated maintenance system.
Descrição
Palavras-chave
Autonomous Maintenance Total Productive Maintenance (TPM) Indicators Microsoft PowerApp 5S DRO 1628 NT Continuous Improvement Operational Efficiency Manutenção autónoma Indicadores Melhoria contínua Eficiência operacional