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Estudo de setups no processo produtivo do pneu: Preparação a quente
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| 12.7 MB | Adobe PDF |
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Abstract(s)
A dissertação correspondente ao presente documento decorre do estágio curricular realizado na Continental Mabor – Indústria de Pneus S.A., cujo objetivo se centra no estudo de setups na preparação a quente, etapa integrante do processo produtivo do pneu. Foi analisada a situação inicialmente encontrada nas extrusoras que produzem pisos e paredes, notando-se variabilidade nas durações dos setups, falta de método estabelecido e oportunidades de melhoria. Seguiu-se a otimização das mudanças de medida a efetuar visando a redução do
tempo improdutivo e aumento do desempenho no funcionamento das máquinas. Procedeu-se a um estudo detalhado das atividades a executar nos vários tipos de setup, tendo depois por base a metodologia Single Minute Exchange of Die para identificação das atividades internas e externas, propondo ações para a sua conversão e simplificação. Utilizando o tempo ganho para mais produção das extrusoras, o número de pneus a produzir diariamente passa de 59.200 unidades para 74.102 a curto ou médio prazo, ou para 76.268 unidades a longo prazo. O Overall Equipment Effectiveness na extrusão de pisos sobe 6,79% na situação mais viável, enquanto na extrusão de paredes ascende 11,29%. Para dar continuidade ao trabalho efetuado há que colocar em prática as melhorias propostas e formar os operadores.
The dissertation arises from the curricular internship carried out at Continental Mabor – Indústria de Pneus S.A., the purpose of which is centred on the analysis of setups within hot preparation, an integral stage of the tire production process. The initial conditions encountered in the extruders responsible for producing treads and sidewalls were examined, revealing variability in setup durations, the absence of standardized procedures and several opportunities for improvement. Subsequently, efforts were directed towards the optimization of changeovers, with the aim of reducing downtime and enhancing machine performance. A comprehensive study was conducted on the activities involved in the different types of setups. The analysis was based on the Single Minute Exchange of Die methodology, which enabled the classification of activities into internal and external as well as the proposal of actions for their conversion and simplification. The time savings achieved were allocated to increasing extruder output, thereby raising daily tire production from 59.200 units to 74.102 units in the short to medium term, or to 76.268 units in the long term. Overall Equipment Effectiveness in tread extrusion was found to increase by 6,79% in the most feasible scenario, while in sidewall extrusion it rose by 11,29%. To ensure the continuity and consolidation of the work developed, it is imperative to implement the proposed improvements and provide adequate training for operators.
The dissertation arises from the curricular internship carried out at Continental Mabor – Indústria de Pneus S.A., the purpose of which is centred on the analysis of setups within hot preparation, an integral stage of the tire production process. The initial conditions encountered in the extruders responsible for producing treads and sidewalls were examined, revealing variability in setup durations, the absence of standardized procedures and several opportunities for improvement. Subsequently, efforts were directed towards the optimization of changeovers, with the aim of reducing downtime and enhancing machine performance. A comprehensive study was conducted on the activities involved in the different types of setups. The analysis was based on the Single Minute Exchange of Die methodology, which enabled the classification of activities into internal and external as well as the proposal of actions for their conversion and simplification. The time savings achieved were allocated to increasing extruder output, thereby raising daily tire production from 59.200 units to 74.102 units in the short to medium term, or to 76.268 units in the long term. Overall Equipment Effectiveness in tread extrusion was found to increase by 6,79% in the most feasible scenario, while in sidewall extrusion it rose by 11,29%. To ensure the continuity and consolidation of the work developed, it is imperative to implement the proposed improvements and provide adequate training for operators.
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Keywords
Setup changeover tire production SMED continuous improvement lean manufacturing Mudança de medida Produção de pneus Melhoria contínua