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Abstract(s)
A indústria automóvel é um dos setores mais exigentes do mercado global, as empresas necessitam de estar em constante evolução e apresentar uma enorme capacidade de adaptação. A capacidade de resposta e a flexibilidade são fundamentais para o sucesso. Uma cultura de excelência e melhoria continua, atuando na otimização dos equipamentos, ferramentas, processos e pessoas conduz à redução de custos e aumento de competitividade.
O crescimento relativamente rápido dos processos e volumes de produção, o aproveitamento de algumas linhas de produção para o fabrico de várias referências, assim como o ajuste dessas mesmas linhas a novos produtos, impede muitas vezes que haja um conhecimento aprofundado da real situação que se encontra no terreno, por parte da Engenharia dos Processos.
Algumas das novas metodologias de análise dos sistemas de produção, permitem uma análise pormenorizada destas situações. De entre outras, o VSM (Value Stream Mapping) tem assumido particular relevo nos últimos tempos. Outras ferramentas e técnicas associadas ao Lean thinking, tais como: SMED (Single Minute Exchange of Die), gestão visual, 5s, standard work, kaizen e ciclo PDCA, são utilizadas pelas empresas para maximizar os ganhos, atuando na eliminação/redução dos desperdícios e melhoraria da eficiência dos processos.
Tomando como referência vários casos de estudo relacionados com a produção de cabos de comando na FICOCABLES, este trabalho visou em primeiro lugar mapear convenientemente esses processos. Numa segunda fase, foi colocado todo o espírito crítico no levantamento inicialmente realizado, com vista a proceder à sua otimização.
Este trabalho revela apenas dois dos vários casos de estudo desenvolvidos, pretendendo mostrar qual a abordagem implementada, e quais os ganhos conseguidos por essa via. A eficiência aumentou de forma considerável, permitindo verificar que é urgente aplicar esta metodologia a todas as linhas de produção. Isso permitiu ganhos consideráveis de produtividade nas linhas de montagem, o que se tem revertido em maiores lucros para a empresa e/ou menor custo para o cliente. A qualidade global tem sido também largamente incrementada por esta via.
The automotive industry is one of the most demanding sectors on the global market. Companies need to be in constant evolution and present an enormous ability to adapt to the new reality. Responsiveness and flexibility are key factors to the success. A culture of excellence and continuous improvement, working on optimization of equipment, tools and processes, as well as reducing people alocated to manual tasks and operations lead to reduced costs and increased competitiveness. The relatively fast growth of the available processes and production volumes, the use of some production lines for the manufacture of various references, as well as the adjustment of these same lines to new products, prevents many times that there is a thorough understanding of the real situation on the ground by the engineering processes. Some of the new methodologies for production systems analysis allow for a detailed understanding of these situations. Among others, the VSM (Value Stream Mapping) has assumed major relevance in recent times. Other tools and techniques associated with Lean thinking, such as: SMED (Single Minute Exchange of Die), visual management, 5Ss, Standard Work, Kaizen and PDCA cycle, are used by companies to maximize the gains in eliminating/reducing wastes and improve the efficiency of the processes. Taking as a reference some case studies related to the production of automotive metallic harness in FICOCABLES, this work first map conveniently these processes. In a second stage, it was carried out a large brainstorming over the survey initially performed, with a view to their optimization. This work reveals only two of the various case studies developed, intending just to show the approach implemented and the gains achieved by this way. The efficiency has increased considerably, allowing verify that it is urgent to apply this methodology to all the production lines of the company. This enabled a significant productivity gain in assembly lines, which reversed in higher profits for the company and/or lower cost for the customer. The overall quality also be largely increased in this way.
The automotive industry is one of the most demanding sectors on the global market. Companies need to be in constant evolution and present an enormous ability to adapt to the new reality. Responsiveness and flexibility are key factors to the success. A culture of excellence and continuous improvement, working on optimization of equipment, tools and processes, as well as reducing people alocated to manual tasks and operations lead to reduced costs and increased competitiveness. The relatively fast growth of the available processes and production volumes, the use of some production lines for the manufacture of various references, as well as the adjustment of these same lines to new products, prevents many times that there is a thorough understanding of the real situation on the ground by the engineering processes. Some of the new methodologies for production systems analysis allow for a detailed understanding of these situations. Among others, the VSM (Value Stream Mapping) has assumed major relevance in recent times. Other tools and techniques associated with Lean thinking, such as: SMED (Single Minute Exchange of Die), visual management, 5Ss, Standard Work, Kaizen and PDCA cycle, are used by companies to maximize the gains in eliminating/reducing wastes and improve the efficiency of the processes. Taking as a reference some case studies related to the production of automotive metallic harness in FICOCABLES, this work first map conveniently these processes. In a second stage, it was carried out a large brainstorming over the survey initially performed, with a view to their optimization. This work reveals only two of the various case studies developed, intending just to show the approach implemented and the gains achieved by this way. The efficiency has increased considerably, allowing verify that it is urgent to apply this methodology to all the production lines of the company. This enabled a significant productivity gain in assembly lines, which reversed in higher profits for the company and/or lower cost for the customer. The overall quality also be largely increased in this way.
Description
Keywords
Linhas de montagem Cabos de comando para automóveis Otimização de processos Mapeamento de processos Lean Manufacturing Value Stream Mapping (VSM) Single Minute Exchange of Die (SMED) Assembly lines Automotive metallic harness Manufacturing processes optimization Manufacturing processes mapping Lean Manufacturing Value Stream Mapping (VSM) Single Minute Exchange of Die (SMED)