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Abstract(s)
Esta tese insere-se no contexto da adoção de metodologias Kaizen na Tecnogravura,
uma empresa dedicada à gravação de cilindros para rotogravura. Estas metodologias,
que implicam o profundo conhecimento do processo produtivo, pretendem promover
a melhoria contínua da qualidade e eficiência.
O objetivo do projeto é analisar o processo de produção atual da linha convencional, estudar cenários alternativos de organização recorrendo a simulação e
recomendar à empresa a alternativa mais promissora. Assim, foram estudados to dos os processos envolvidos, desde a preparação do cilindro para gravura e do design
para gravação até à gravação do cilindro, assim como as linhas de produção exis tentes compostas por uma linha convencional e duas linhas semiautomáticas, que
mecaniza alguns transportes e realiza o setup dos autómatos.
Procedeu-se ao levantamento de soluções comerciais de recolha e análise em
tempo real de indicadores de desempenho do processo produtivo e de projetos académicos relacionados. Todas as soluções e projetos foram analisados e comparados,
incluindo as soluções em uso na empresa, para ajudar a escolher os indicadores mais
adequados para a simulação.
A simulação contemplou vários cenários de reestruturação da linha convencional,
nomeadamente de linearização do fluxo produtivo, adoção de tapetes rolantes para
transporte, de forma a reduzir a fatiga dos operadores e permitir o manuseamento
eficiente do produto, e balanceamento da carga entre estações de trabalho. De
seguida, foram analisados e escolhidos os indicadores de desempenho a utilizar na
simulação e recolhidos os dados necessários. O cenário que combina a linearização
do fluxo produtivo com o transporte por tapete rolante simplifica todo o processo e
reduz a distância percorrida pelos operadores.
This thesis is set in the context of the adoption of Kaizen methodologies at Tec nogravura, a company dedicated to engraving cylinders for rotogravure. These methodologies, which involve in-depth knowledge of the production process, aim to promote continuous improvement in quality and efficiency. The aim of the project is to analyse the current production process of the con ventional line, study alternative scenarios for organising the shop floor through simulation and recommend the most promissing alternative to the company. Thus, all the processes involved were studied, from preparing the cylinder for engraving and the design for engraving to engraving the cylinder, as well as the existing production lines consisting of a conventional line and two semi-automatic lines, which mechanises some transports and carries out the setup of the machines. A survey was carried out of commercial solutions for collecting and analysing production process performance indicators in real time and of related academic projects. All the solutions and projects were analysed and compared, including the solutions in use at the company, in order to choose the most suitable indicators for the simulation. The simulation included various scenarios for restructuring the conventional line, namely linearising the production flow, adopting conveyor belts for transport to reduce operator fatigue and enable efficient product handling, and balancing the production load between processes and workstations. The performance indicators to be used in the simulation were then analysed, chosen and the required data gathered. The scenario combining the linearisation of the production flow with conveyor belt transport not only simplifies the entire process, but minimises the distance travelled by operators.
This thesis is set in the context of the adoption of Kaizen methodologies at Tec nogravura, a company dedicated to engraving cylinders for rotogravure. These methodologies, which involve in-depth knowledge of the production process, aim to promote continuous improvement in quality and efficiency. The aim of the project is to analyse the current production process of the con ventional line, study alternative scenarios for organising the shop floor through simulation and recommend the most promissing alternative to the company. Thus, all the processes involved were studied, from preparing the cylinder for engraving and the design for engraving to engraving the cylinder, as well as the existing production lines consisting of a conventional line and two semi-automatic lines, which mechanises some transports and carries out the setup of the machines. A survey was carried out of commercial solutions for collecting and analysing production process performance indicators in real time and of related academic projects. All the solutions and projects were analysed and compared, including the solutions in use at the company, in order to choose the most suitable indicators for the simulation. The simulation included various scenarios for restructuring the conventional line, namely linearising the production flow, adopting conveyor belts for transport to reduce operator fatigue and enable efficient product handling, and balancing the production load between processes and workstations. The performance indicators to be used in the simulation were then analysed, chosen and the required data gathered. The scenario combining the linearisation of the production flow with conveyor belt transport not only simplifies the entire process, but minimises the distance travelled by operators.
Description
Keywords
Kaizen Flexsim Performance indicators Industrial planning Electroplating Rotogravure cylinders