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Advisor(s)
Abstract(s)
Esta dissertação foi realizada num contexto industrial, numa empresa que utiliza e reutiliza a cortiça, assim como outros materiais para criar novos produtos, dando aos mesmos uma nova utilidade. Devido à elevada necessidade de uma maior produtividade e eficiência dos equipamentos, o objetivo principal deste trabalho foi implementar dois pilares da metodologia TPM na empresa em questão. Dada a elevada dimensão da empresa, foi decidido que inicialmente apenas seria necessário focar em duas áreas. O trabalho desenvolvido dividiu-se em várias etapas. Inicialmente foi realizada uma análise das criticidades dos equipamentos de cada linha, e posteriormente foram analisadas as solicitações entre julho de 2017 e julho de 2019, de forma a retirar os problemas mais recorrentes dos equipamentos críticos. Após esta análise, foi possível perceber que as manutenções autónomas e preventivas não estavam a ser realizadas pelos operadores, tendo por isso que ser alteradas e melhoradas, sendo esta efetuada em conjunto com a direção de cada área, com o objetivo de demonstrar às mesmas a importância e as melhorias que poderiam trazer a cada uma destas, diminuindo os tempos de paragem, o que consequentemente promove a um incremento da produção. Devido à implementação do SAP, não foi possível obter dados referentes à época atual na fábrica, de forma a comparar com os obtidos durante este trabalho. Contudo, conseguiu-se verificar quais as avarias que seriam referentes à falta de intervenções, sendo associado um custo indireto de paragem das linhas devido a essas avarias, concluindo-se que, no total, as principais máquinas de cada linhas, durante um ano, trouxeram um elevado prejuízo, como ficou demonstrado. Sendo assim, foram criados novos planos de manutenção autónoma e preventiva, específicos para os equipamentos mais importantes de cada área, e foram também criadas OPL’s - One Point Lessons, ou seja, procedimentos que ilustram as Operações Standard, de manutenção preventiva, padronizando e facilitando as intervenções nos equipamentos críticos. No final do estágio, também foi necessário iniciar a implementação do TPM na Oficina Auto, local de manutenção dos equipamentos utilizados para transportar material. Aqui, iniciou-se para implementação dos 5S e foram discutidas diversas ideias de como melhorar e organizar o local.
This dissertation was carried out in an industrial context, in a company that uses and reuses cork and other materials to create new products, giving them a new use. Due to the high need for greater productivity and equipment efficiency, the main objective of this work was to implement two pillars of the TPM methodology in the company in question. Given the large size of the company, it was decided that, initially, it would only be necessary to focus on two areas. The work developed was divided into several stages. Initially, an analysis of the criticalities of the equipment on each line was performed, and then the requests between July 2017 and July 2019 were analyzed in order to remove the most recurrent breakdowns of the critical equipment. After this analysis, it was possible to realize that the autonomous and preventive maintenance was not being carried out by the operators, and therefore had to be changed and improved. This was done in conjunction with the management of each area, with the goal of demonstrating to them the importance and the improvements that could bring to each of them, reducing downtime, which consequently increases production. Due to the implementation of SAP, it was not possible to obtain data for the current time in the factory in order to compare with those obtained between July 2017 and July 2019, however, it was possible to verify which breakdowns would be related to the lack of interventions, being associated with an indirect cost of stopping the lines due to these breakdowns, concluding that in total the main machines of each line, during a year, brought a great loss, as it will be shown. That way, new autonomous and preventive maintenance plans were created, specific for the most important equipment in each area and OPL's - One Point Lessons - were also created, i.e., procedures that illustrate the Standard Operations of preventive maintenance, standardizing and facilitating interventions in critical equipment. At the end of the internship, it was also necessary to start the implementation of TPM in the Auto Workshop, place of maintenance of the equipment used to transport material. Here, we started to implement the 5S and discussed several ideas on how to improve and organize the site.
This dissertation was carried out in an industrial context, in a company that uses and reuses cork and other materials to create new products, giving them a new use. Due to the high need for greater productivity and equipment efficiency, the main objective of this work was to implement two pillars of the TPM methodology in the company in question. Given the large size of the company, it was decided that, initially, it would only be necessary to focus on two areas. The work developed was divided into several stages. Initially, an analysis of the criticalities of the equipment on each line was performed, and then the requests between July 2017 and July 2019 were analyzed in order to remove the most recurrent breakdowns of the critical equipment. After this analysis, it was possible to realize that the autonomous and preventive maintenance was not being carried out by the operators, and therefore had to be changed and improved. This was done in conjunction with the management of each area, with the goal of demonstrating to them the importance and the improvements that could bring to each of them, reducing downtime, which consequently increases production. Due to the implementation of SAP, it was not possible to obtain data for the current time in the factory in order to compare with those obtained between July 2017 and July 2019, however, it was possible to verify which breakdowns would be related to the lack of interventions, being associated with an indirect cost of stopping the lines due to these breakdowns, concluding that in total the main machines of each line, during a year, brought a great loss, as it will be shown. That way, new autonomous and preventive maintenance plans were created, specific for the most important equipment in each area and OPL's - One Point Lessons - were also created, i.e., procedures that illustrate the Standard Operations of preventive maintenance, standardizing and facilitating interventions in critical equipment. At the end of the internship, it was also necessary to start the implementation of TPM in the Auto Workshop, place of maintenance of the equipment used to transport material. Here, we started to implement the 5S and discussed several ideas on how to improve and organize the site.
Description
Keywords
Manutenção Manutenção Preventiva Manutenção Autónoma Melhoria Continua Maintenance Preventive Maintenance Autonomous Maintenance Continues Improvement