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Abstract(s)
Atualmente, devido a um mercado cada vez mais competitivo, o sucesso de uma empresa depende da sua capacidade de adaptação às exigências do mercado. Assim, as empresas procuram cada vez mais integrar as metodologias Lean nos seus processos produtivos, de forma a aumentar o nível de eficiências dos seus processos. A presente dissertação, desenvolvida na unidade fabril Toyota Caetano Portugal, teve como principal objetivo a melhoria do layout do armazém de abastecimento à linha de montagem do Land Cruiser série 70, utilizando metodologias Lean. Nesse sentido, procedeu-se ao levantamento do estado atual do armazém, de forma a identificar as oportunidades de melhoria. Após esta observação foi possível compreender que a disposição do material nas racks e o layout do armazém eram desadequados principalmente para o processo de picking, causando várias deslocações desnecessárias. Tendo por base a filosofia Lean foram apresentadas várias propostas de melhoria para a mitigação dos problemas identificados. Assim, inicialmente, foram elaborados documentos standard para os postos de trabalhos logísticos que auxiliaram no estudo realizado para a alteração de takt time. Isto é, permitiu compreender se a mão de obra tinha capacidade para a produção de 11 unidades diárias. De modo que a alteração do layout fosse eficiente, foi necessário, primeiro, uma reorganização do material no supermercado da Montagem Final. Como houve alteração de takt time e, consequente transferência de material de um supermercado para outro, esta alteração permitiu que fosse apenas necessário a aquisição de 4 racks ao invés de 12, resultando numa poupança de 4.460€. Finalizada esta tarefa, procedeu-se à reorganização das racks. A implementação destas duas melhorias originou uma redução significativa das deslocações de dollies cheios e a transformação de deslocações com dollies em deslocações sem dollies. No que concerne ao picking dos dollies abastecidos pelo mizusumashi, obteve-se uma redução de cerca de 29,02% de distância percorrida pelo operador do picking. Relativamente aos dollies abastecidos sem mizusumashi, foi possível transformar 10,40% das deslocações com dolly em deslocações sem dolly, o que incorre numa redução do nível de risco ergonómico da tarefa. Quanto ao layout da Célula de Pré-Montagens elaborou-se uma reorganização das bancadas de trabalho e das racks permitindo que o colaborador executasse todas as tarefas atempadamente, isto é, dentro do takt time estipulado (42,5 minutos). À priori da implementação da proposta de melhoria, o colaborador alocado às pré-montagens necessitava de auxílio para a execução das suas tarefas dentro do takt time.
Currently, due to an increasingly competitive market, the success of a company depends on its ability to adapt to market demands. Thus, companies are increasingly seeking to integrate Lean methodologies in their production processes, to increase the level of efficiency of their processes. This dissertation, developed in Toyota Caetano Portugal, had as main objective the improvement of the warehouse layout to supply the assembly line of the Land Cruiser 70 series, using Lean methodologies. In this sense, the current state of the warehouse was surveyed, to identify opportunities for improvement. After this observation it was possible to understand that the arrangement of the material on the racks and the warehouse layout was inadequate, especially for the picking process, causing several unnecessary trips. Based on the Lean philosophy, several improvement proposals were presented to mitigate the problems identified. Thus, initially, standard documents were prepared for the logistical jobs that assisted in the study conducted for the change in takt time. That is, it allowed understanding whether the workforce had the capacity to produce 11 units per day. For the layout change to be efficient, it was first necessary to reorganize the material in the Final Assembly supermarket. As there was a change in takt time and consequent transfer of material from one supermarket to another, this change allowed the acquisition of only 4 racks instead of 12, resulting in a savings of 4.460€. Once this task was completed, the racks were reorganized. The implementation of these two improvements resulted in a significant reduction in the number of trips with full dollies and the transformation of trips with dollies into trips without dollies. As far as the picking of dollies supplied by the mizusumashi is concerned, a reduction of about 29,02% in the distance traveled by the picking operator was achieved. Regarding the dollies supplied without mizusumashi, it was possible to transform 10,40% of the trips with dolly into trips without dolly, which reduces the ergonomic risk level of the task. As for the layout of the pre-assembly cell, the workbenches and racks were reorganized, allowing the employee to perform all tasks on time, i.e., within the stipulated takt time (42,5 minutes). Prior to the implementation of the improvement proposal, the employee allocated to pre-assemblies needed help to perform his tasks within the takt time.
Currently, due to an increasingly competitive market, the success of a company depends on its ability to adapt to market demands. Thus, companies are increasingly seeking to integrate Lean methodologies in their production processes, to increase the level of efficiency of their processes. This dissertation, developed in Toyota Caetano Portugal, had as main objective the improvement of the warehouse layout to supply the assembly line of the Land Cruiser 70 series, using Lean methodologies. In this sense, the current state of the warehouse was surveyed, to identify opportunities for improvement. After this observation it was possible to understand that the arrangement of the material on the racks and the warehouse layout was inadequate, especially for the picking process, causing several unnecessary trips. Based on the Lean philosophy, several improvement proposals were presented to mitigate the problems identified. Thus, initially, standard documents were prepared for the logistical jobs that assisted in the study conducted for the change in takt time. That is, it allowed understanding whether the workforce had the capacity to produce 11 units per day. For the layout change to be efficient, it was first necessary to reorganize the material in the Final Assembly supermarket. As there was a change in takt time and consequent transfer of material from one supermarket to another, this change allowed the acquisition of only 4 racks instead of 12, resulting in a savings of 4.460€. Once this task was completed, the racks were reorganized. The implementation of these two improvements resulted in a significant reduction in the number of trips with full dollies and the transformation of trips with dollies into trips without dollies. As far as the picking of dollies supplied by the mizusumashi is concerned, a reduction of about 29,02% in the distance traveled by the picking operator was achieved. Regarding the dollies supplied without mizusumashi, it was possible to transform 10,40% of the trips with dolly into trips without dolly, which reduces the ergonomic risk level of the task. As for the layout of the pre-assembly cell, the workbenches and racks were reorganized, allowing the employee to perform all tasks on time, i.e., within the stipulated takt time (42,5 minutes). Prior to the implementation of the improvement proposal, the employee allocated to pre-assemblies needed help to perform his tasks within the takt time.
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Keywords
Layout Lean Melhoria Contínua Picking Armazenamento Continuous Improvement Warehousing