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Abstract(s)
A revisão, atualização e melhoria contínua dos processos produtivos, revelam-se um ponto importante para a possível otimização de qualquer indústria. Este projeto foi desenvolvido no âmbito da dissertação do Mestrado em Engenharia Mecânica e consistiu, inicialmente, no estudo e análise dos ativos e ferramentas de gestão previamente utilizados no departamento de manutenção industrial (DMI) da empresa Efacec Power Solutions (EPS). O passo seguinte passou pelo desenvolvimento da presente dissertação que, seguindo uma metodologia de Action Research (AR), funcionou como uma pesquisa de pressupostos, metodologias e ferramentas a implementar na empresa. Assim, o principal objetivo deste trabalho resume-se à otimização da gestão da manutenção preventiva (MP), adequando e atualizando os métodos já utilizados, com o apoio da Indústria 4.0 (I4.0) e aplicação de uma estratégia baseada na metodologia TPM (Total Productive Maintenance). Com vista a apoiar a tomada de decisão, foi elaborada uma análise aos equipamentos, com maior ênfase nos considerados críticos para a empresa. Após o estudo dos equipamentos, foi definida uma nova restruturação na gestão do plano de Manutenção Preventiva, com base nas metodologias TPM, que resultou na implementação de intervenções de Manutenção Autónoma (MA), otimização dos manuais de manutenção preventiva (MMP) e desenvolvimento de uma ferramenta associada, otimização do layout do DMI e higienização do ERP (Enterprise Resource Planning) e ainda o desenvolvimento de ferramentas para o controlo e registo de KPI’s. Concluído o trabalho, foram observadas melhorias significativas ao nível da gestão da manutenção, entre as quais foi identificada uma redução do tempo de desperdício na realização de MP, cerca de 60%, devido à revisão realizada aos MMP e à introdução de uma tecnologia mais user friendly para os operadores, assim como uma diminuição do número de intervenções corretivas nos equipamentos onde foi aplicada MA, com uma média correspondente a 41%. Por fim, foram ainda introduzidos KPI’s relativos ao levantamento dos tempos das atividades, tais como, MTTA, MTTR, MRT, MDT, MTBF.
The review, updating and continuous improvement of the production processes are meaningful for the potential optimization of any industry. This project was developed as part of the final internship of the Master’s in Mechanical Engineering and consisted of the study and analysis of assets and management tools previously used in the industrial maintenance department at Efacec Power Solutions, S. A. (EPS). The next step was the development of this dissertation following an Action Research (AR) methodology, which worked as an assumption research with different methodologies and tools to be implemented in the company. Therefore, the main goal of this work sum up to the optimization of the Preventive Maintenance Management, adapting and improving the methods already used, supported by Industry 4.0 and application of a strategy based on the TPM methodology. In order to support the decision-making, an analysis of the equipment was carried out, with greater emphasis on those considered critical for the company. Then, a new restructuring of the Preventive Maintenance Plan Management was defined, based on TPM methodologies, which resulted in the implementation of Autonomous Maintenance, improvement of preventive maintenance records and development of a user-friendly tool, optimization of the department layout, cleansing of the ERP data base and the development of tools for recording and control of KPI’s. Once the work has been completed, significant improvements were noted in terms of maintenance management. A reduction in waste of time during the execution of preventive maintenance was identified, in the order of 60%, due to the revision of the preventive maintenance records and the introduction of a user-friendly technology for operators, as well as a decrease in the number of corrective interventions in assets where AM was applied, with an average corresponding to 41%. Finally, KPIs related to the survey of activity times were also introduced, such as MTTA, MTTR, MRT, MDT and MTBF
The review, updating and continuous improvement of the production processes are meaningful for the potential optimization of any industry. This project was developed as part of the final internship of the Master’s in Mechanical Engineering and consisted of the study and analysis of assets and management tools previously used in the industrial maintenance department at Efacec Power Solutions, S. A. (EPS). The next step was the development of this dissertation following an Action Research (AR) methodology, which worked as an assumption research with different methodologies and tools to be implemented in the company. Therefore, the main goal of this work sum up to the optimization of the Preventive Maintenance Management, adapting and improving the methods already used, supported by Industry 4.0 and application of a strategy based on the TPM methodology. In order to support the decision-making, an analysis of the equipment was carried out, with greater emphasis on those considered critical for the company. Then, a new restructuring of the Preventive Maintenance Plan Management was defined, based on TPM methodologies, which resulted in the implementation of Autonomous Maintenance, improvement of preventive maintenance records and development of a user-friendly tool, optimization of the department layout, cleansing of the ERP data base and the development of tools for recording and control of KPI’s. Once the work has been completed, significant improvements were noted in terms of maintenance management. A reduction in waste of time during the execution of preventive maintenance was identified, in the order of 60%, due to the revision of the preventive maintenance records and the introduction of a user-friendly technology for operators, as well as a decrease in the number of corrective interventions in assets where AM was applied, with an average corresponding to 41%. Finally, KPIs related to the survey of activity times were also introduced, such as MTTA, MTTR, MRT, MDT and MTBF
Description
Keywords
Gestão do Plano de Manutenção Preventiva Manutenção Produtiva Total Manutenção Preventiva Manutenção Autónoma Planeamento de Recursos Empresariais Digitalização Indicadores de desempenho Preventive Maintenance Plan Management Total Productive Maintenance Preventive Maintenance Autonomous Maintenance Enterprise Resource Planning Digitalization Performance Indicators