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Advisor(s)
Abstract(s)
Hoje em dia, e principalmente na indústria automóvel, as empresas necessitam cada vez mais de responder às necessidades dos clientes de forma rápida, eficaz e de uma forma eficiente. Para tal, qualquer forma de desperdício como sucede nas paragens devido a operações de setup, prejudicam a empresa, não só pelo aumento no tempo de resposta como também em custos resultantes do aumento dos níveis de inventário. Este trabalho foi realizado num ambiente real de uma empresa industrial, e teve dois objetivos principais. O primeiro foi a redução de tempos de setup em três prensas mecânicas cuja média dos tempos de setup se encontrava inicialmente acima de uma hora, criando um impacto negativo na disponibilidade das prensas em questão. O segundo, consistiu no planeamento da instalação de uma nova prensa mecânica e a respetiva redução de tempo de setup. Neste segundo objetivo, as atividades desenvolvidas no presente trabalho focaram-se na definição das propostas de investimento e técnicas mecânicas de modo a garantir um tempo de setup reduzido. Inicialmente recolheram-se os dados sobre o estado inicial da operação de setup em prensas, com o foco principal no entendimento do processo, assim como a identificação das atividades de maior duração e com maior potencialidade para melhoria. Aplicou-se a metodologia SMED em conjunto com um grupo de técnicas de análise e ferramentas de qualidade para sustentar a transformação necessária em cada fase SMED, sendo o exemplo destas o ciclo PDCA, o diagrama de Ishikawa, 5W2H, gestão visual, análise ABC e a metodologia dos 5S. Após a implementação das ferramentas de melhoria, verificou-se uma clara redução no tempo do setup em qualquer uma das prensas estudadas. Algumas propostas embora não implementadas, foram validadas, potencializando assim a possibilidade de serem introduzidas pela empresa no futuro.
Nowadays, especially in the automobile industry, companies increasingly need to respond to customer needs quickly, effectively and efficiently. To do this, any form of waste, such as stoppages due to setup operations, is detrimental to the company, not only because of the increase in response time, but also in costs resulting from increased inventory levels. This work was carried out in a real environment of an industrial company, and had two main objectives. The first was the reduction of setup times in three mechanical presses whose average setup times were initially over one hour, creating a negative impact on the availability of the presses in question. The second one consisted in the planning of the installation of a new mechanical press and the respective reduction of setup time. In this second objective, the activities developed in the present work focused on the definition of investment proposals and mechanical procedures in order to guarantee a reduced setup time. Initially, the data was collected on the initial state of the setup exchange in power presses, with the main focus being on the understanding of the process, as well as identification of activities with longer duration and potential for improvement. The SMED methodology was applied in conjunction with a group of analysis and quality tools to support the information needed in each SMED phase, such as the PDCA cycle, the Ishikawa diagram, 5W2H, visual management, ABC analysis and the methodology 5S. After the implementation of the improvement tools, there was a clear decrease in setup time in all of the presses studied. Some proposals, although not implemented, were validated, thus enhancing the possibility of being introduced by the company in the future.
Nowadays, especially in the automobile industry, companies increasingly need to respond to customer needs quickly, effectively and efficiently. To do this, any form of waste, such as stoppages due to setup operations, is detrimental to the company, not only because of the increase in response time, but also in costs resulting from increased inventory levels. This work was carried out in a real environment of an industrial company, and had two main objectives. The first was the reduction of setup times in three mechanical presses whose average setup times were initially over one hour, creating a negative impact on the availability of the presses in question. The second one consisted in the planning of the installation of a new mechanical press and the respective reduction of setup time. In this second objective, the activities developed in the present work focused on the definition of investment proposals and mechanical procedures in order to guarantee a reduced setup time. Initially, the data was collected on the initial state of the setup exchange in power presses, with the main focus being on the understanding of the process, as well as identification of activities with longer duration and potential for improvement. The SMED methodology was applied in conjunction with a group of analysis and quality tools to support the information needed in each SMED phase, such as the PDCA cycle, the Ishikawa diagram, 5W2H, visual management, ABC analysis and the methodology 5S. After the implementation of the improvement tools, there was a clear decrease in setup time in all of the presses studied. Some proposals, although not implemented, were validated, thus enhancing the possibility of being introduced by the company in the future.
Description
Keywords
Setup SMED Ciclo PDCA Melhoria Continua Metodologia 5S Plano de Ação 5W2H Diagrama de Ishikawa G estão Visual Padronização de Trabalho Análise ABC PDCA Cycle Continuous Improvement 5s Methodology 5w2h Action Plan Ishikawa Diagram Visual Management Work Standardization ABC Analysis