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Abstract(s)
Os sistemas produtivos das empresas têm de ser redesenhados e redefinidos para fazer face à grande competitividade existente no mercado global atual. O lean, ou sistema de produção da Toyota (TPS – Toyota Production System), defende a utilização dos recursos mínimos necessários em cada atividade, e o seu objetivo é o de identificar e remover qualquer atividade existente no processo ou cadeia de abastecimento que não acrescente valor.
Este trabalho foi desenvolvido na secção de contracolagem de uma empresa pertencente ao setor da cartonagem. Neste setor, são produzidos os planos que dão origem às embalagens, através da união entre o cartão ondulado e os planos impressos no setor anterior. Este trabalho foi desenvolvido com base no ciclo PDCA, tendo em consideração as suas quatro etapas distintas. Em primeiro lugar, foi efetuada uma análise do estado inicial do setor, através da recolha de dados nas duas linhas existentes, e concluiu-se que existia uma grande variabilidade nos parâmetros do processo utilizados em trabalhos iguais. Procedeu-se à identificação dos principais problemas no processo, e concluiu-se que planos empenados e planos descolados, eram os principais motivos de preocupação. Foram implementadas cartas de controlo para a cola de amido e, através da análise destas e da utilização de diagramas causa-efeito, foram implementadas diversas alterações no circuito da cola, e na própria receita da cola.
Diminui-se a pressão de vapor da caldeira de 12 bar para 8 bar, e implementou-se uma tabela de temperaturas a fornecer aos papéis, em função da sua gramagem.
Os resultados obtidos demonstram que ocorreu uma diminuição na percentagem de desperdícios no setor, que rondavam os 9 a 12%, para valores próximos de 4%. Em relação ao consumo da cola de amido, este baixou de 11 g/m2 para os 8 g/m2 . O consumo energético, nomeadamente de gás, teve uma poupança na ordem dos 9%.
Devido ao seu caráter inovador e aos resultados positivos obtidos, este trabalho representa um pequeno contributo para o setor.
Companies’ production systems must be redesign and redefined to face the competitiveness demand existent in today’s global market. Lean manufacturing or TPS (Toyota Production System) says that minimum resources needed in each activity should be used and its goal is identifying and removing any existing activity in the process or in the supply-chain that does not add value. The present work was developed in the litho-lamination sector of a company that belongs to the cardboard industry. In this sector are produced plans resulting from the union between corrugated cardboard produced and the sheets printed in the previous sector. The PDCA cycle was the methodology followed during the execution of the work presented. In first place, the initial state of the sector was analyzed by data collection in both existent lines and it was concluded that a great variability was implemented in the parameters used in the process for similar works. The main problems in the process were identified and it was concluded that warp and detached plans were the main reasons of concern. It was implemented a set of measures to reduce these incidences. Control charts were implemented to the starch glue and through the analysis of these charts and cause-effect diagrams several changes to the starch glue circuit and to its own recipe were implemented. The steam pressure of the boiler was reduced from 12 bar to 8 bar and a table with temperatures regarding each paper weight was implemented. The results obtained show that the percentage of waste in the sector was reduced from values ranging between 9 and 12% to values around 4%. Regarding starch glue consumption, it dropped from 11 g/m2 to 8 g/m2. The energy consumption, namely gas, had a saving of 9%. Due to its innovative character and the positive results obtained, this work represents a small contribute to the sector.
Companies’ production systems must be redesign and redefined to face the competitiveness demand existent in today’s global market. Lean manufacturing or TPS (Toyota Production System) says that minimum resources needed in each activity should be used and its goal is identifying and removing any existing activity in the process or in the supply-chain that does not add value. The present work was developed in the litho-lamination sector of a company that belongs to the cardboard industry. In this sector are produced plans resulting from the union between corrugated cardboard produced and the sheets printed in the previous sector. The PDCA cycle was the methodology followed during the execution of the work presented. In first place, the initial state of the sector was analyzed by data collection in both existent lines and it was concluded that a great variability was implemented in the parameters used in the process for similar works. The main problems in the process were identified and it was concluded that warp and detached plans were the main reasons of concern. It was implemented a set of measures to reduce these incidences. Control charts were implemented to the starch glue and through the analysis of these charts and cause-effect diagrams several changes to the starch glue circuit and to its own recipe were implemented. The steam pressure of the boiler was reduced from 12 bar to 8 bar and a table with temperatures regarding each paper weight was implemented. The results obtained show that the percentage of waste in the sector was reduced from values ranging between 9 and 12% to values around 4%. Regarding starch glue consumption, it dropped from 11 g/m2 to 8 g/m2. The energy consumption, namely gas, had a saving of 9%. Due to its innovative character and the positive results obtained, this work represents a small contribute to the sector.
Description
Keywords
Lean Contracolagem Cola de Amido Empeno Desperdícios Litho-lamination Starch Glue Warp Waste