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Abstract(s)
A presente dissertação no âmbito industrial traduz o caso de estudo com enfoque na otimização de
lotes de produção, desenvolvido numa indústria automóvel, KIRCHHOFF Automotive.
Com a crescente competitividade no mercado do retalho urge a necessidade das empresas se
diferenciarem dos demais concorrentes e aumentarem a sua flexibilidade de modo a reponderem,
de forma expedita, às necessidades do mercado.
Desta forma, o objetivo deste projeto passa pela otimização do processo de estampagem a frio,
que consequentemente proporciona uma redução nos custos operacionais, maior aumento da
disponibilidade das máquinas, e maior eficiência no processo produtivo. Mais concretamente na
otimização das bobines de aço utlizadas no processo de estampagem, calculando as dimensões
ideais para os lotes de produção definidos, de forma a reduzir o número de bobines utilizadas no
processo produtivo.
O projeto desenvolvido passa pela redução do tempo despendido nas mudanças de bobines ao
longo das produções calculando a bobine ideal para cada lote. Em grande parte das produções é
necessário utilizar várias bobines devido à incorreta dimensão das mesmas, o que obriga a paragens
recorrentes da produção. Sendo possível reduzir o número de bobines utilizadas por lote, o número
de trocas irá logicamente ser inferior, implicando um espaço de tempo menor para produzir o
mesmo número de peças.
Nesta atividade é ainda abordado o fluxo logístico desde da produção da bobine na siderurgia até
à chegada da mesma à prensa de estampagem, de forma a avaliar o seu percurso e tentar eliminar
movimentações que não acrescentem valor ao produto, e consequentemente diminuir os custos
associados ao transporte.
A metodologia desenvolvida foi baseada na filosofia Six Sigma, nomeadamente a Metodologia
DMAIC. A análise e avaliação do caso de estudo foram suportadas pelas diferentes etapas
constituintes da respetiva metodologia, assim como o suporte de dados do sistema ERP
trabalhados como ficheiros Excel.
Desta forma, foi possível alcançar o número e tamanho das bobines ideias para produção, tendo
em conta as limitações sentidas ao longo do caso de estudo. Para além da otimização do número e
características das bobines, também foi possível atingir uma redução de 41 % do custo de mão de
obra e redução de 25,4% da área dedicada a armazenamento de bobines.
This industrial dissertation is a case study focusing on the optimization of production batches, developed in the automotive industry, KIRCHHOFF Automotive. Due to the growing competitiveness of the retail market and in order to quickly respond to market needs, companies started feeling the necessity to differentiate themselves from other competitors and increase their flexibility. Thus, the goal of this project is to optimize the cold stamping process, which consequently leads to a reduction in operating costs, a greater increase in machine availability and greater efficiency in the production process. More specifically, optimizing the steel coils used in the stamping process, calculating the ideal dimensions for the defined production batches, aiming to reduce the number of coils used in the production process. The project involves reducing the time spent changing reels during production by calculating the ideal reel for each batch. A large number of production runs require the use of several reels due to their incorrect size, which leads to recurring production stoppages. If it is possible to reduce the number of reels used per batch, the number of changes will logically be lower, meaning that it will take less time to produce the same number of pieces. This activity also covers the logistical flow from the production of the coil in the steelworks to its arrival at the stamping press, in order to evaluate its route and try to eliminate movements that do not add value to the product and consequently reduce the costs associated with transportation. The methodology developed was based on the Six Sigma philosophy, namely the DMAIC Methodology. The analysis and evaluation of the case study was supported by the different stages of the respective methodology, as well as the support of data from the ERP system processed as Excel files. Consequently, it was possible to achieve the ideal number and size of reels for production, taking into account the limitations experienced throughout the case study. In addition to optimizing the number and characteristics of the reels, it was also possible to achieve a 41% reduction in labor costs and a 25.4% reduction in the area dedicated to reel storage.
This industrial dissertation is a case study focusing on the optimization of production batches, developed in the automotive industry, KIRCHHOFF Automotive. Due to the growing competitiveness of the retail market and in order to quickly respond to market needs, companies started feeling the necessity to differentiate themselves from other competitors and increase their flexibility. Thus, the goal of this project is to optimize the cold stamping process, which consequently leads to a reduction in operating costs, a greater increase in machine availability and greater efficiency in the production process. More specifically, optimizing the steel coils used in the stamping process, calculating the ideal dimensions for the defined production batches, aiming to reduce the number of coils used in the production process. The project involves reducing the time spent changing reels during production by calculating the ideal reel for each batch. A large number of production runs require the use of several reels due to their incorrect size, which leads to recurring production stoppages. If it is possible to reduce the number of reels used per batch, the number of changes will logically be lower, meaning that it will take less time to produce the same number of pieces. This activity also covers the logistical flow from the production of the coil in the steelworks to its arrival at the stamping press, in order to evaluate its route and try to eliminate movements that do not add value to the product and consequently reduce the costs associated with transportation. The methodology developed was based on the Six Sigma philosophy, namely the DMAIC Methodology. The analysis and evaluation of the case study was supported by the different stages of the respective methodology, as well as the support of data from the ERP system processed as Excel files. Consequently, it was possible to achieve the ideal number and size of reels for production, taking into account the limitations experienced throughout the case study. In addition to optimizing the number and characteristics of the reels, it was also possible to achieve a 41% reduction in labor costs and a 25.4% reduction in the area dedicated to reel storage.
Description
Keywords
DMAIC Lote sizing Steel coils Case study OEE Lote económico, Bobines de aço Caso estudo