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Advisor(s)
Abstract(s)
Atualmente, as preocupações ambientais estão cada vez mais enraizadas na nossa sociedade. Esta crescente preocupação reflete-se nas estratégias implementadas pelas organizações, estando estas cada vez mais focadas em estratégias eco-friendly, tanto pela sua vertente estratégica como pela sua responsabilidade social. Assim, a CaetanoBus e a Toyota Caetano Portugal acompanharam esta tendência atuando numa área de extrema importância, a mobilidade elétrica. Uma vez que o mercado se está a tornar cada vez mais competitivo nestas áreas é necessário garantir a capacidade de adaptação da organização à volatilidade do mesmo e a eficiência dos processos existentes, sendo que os fluxos logísticos interpretam um papel de destaque. É no âmbito dos fluxos e processos de logística interna que se insere esta dissertação, desenvolvida na fábrica da Toyota Caetano Portugal, em Ovar, na linha de chassis elétricos para autocarros. O objetivo principal deste projeto é o da melhoria e otimização de processos logísticos, recorrendo a ferramentas Lean. Primeiramente, procedeu-se à realização de uma revisão bibliográfica, de modo a criar uma base teórica. Seguidamente, foi necessário realizar o diagnóstico e mapeamento do estado atual dos processos logísticos da linha de chassis elétricos, de modo a identificar quais os problemas existentes e priorizar estes em termos de urgência de ação. Após este diagnóstico foi possível concluir que as áreas que careciam de ação imediata, devido ao seu impacto nos fluxos logísticos e de produção, tratava-se das operações de picking do material, os abastecimentos do mesmo à linha de produção e o layout do armazém logístico. Assim, tendo como base a filosofia Lean e as ferramentas inerentes a esta, como o Standard Work, 5S, a filosofia Kaizen e Gestão Visual foram apresentadas e implementadas diversas propostas de melhoria para a mitigação dos problemas previamente identificados. Relativamente à operação de picking do material procedeu-se à conceção de caixas picking adaptadas à segunda geração de chassis, bem como o estudo de meios de abastecimento do material à linha de produção adequados a este novo modelo e à natureza dos materiais. Com a implementação destas melhorias nas operações de picking do material para caixas obteve-se uma redução de 44,6% do tempo despendido na operação. Devido à implementação de documentos standard para estas operações, as listas de picking, estima-se que a duração desta tarefa poderá sofrer uma diminuição acrescida de cerca de 30%. No que concerne os abastecimentos à linha, para além de se ter alcançado uma redução do nível de risco das operações, devido à implementação de um corredor de abastecimento e ao uso de meios adequados para a tarefa, reduziu-se em 18,4% a duração deste processo logístico. Quanto ao layout do armazém logístico, o dimensionamento do mesmo para duas semanas de produção, a aplicação de uma Análise ABC e de ferramentas de Gestão Visual incorreu numa diminuição em cerca de 50% na tarefa de levantamento de material ao armazém geral, tendo esta redução um grande impacto no Takt Time dos processos de logística interna da linha de chassis elétricos.
Nowadays, environmental concerns are deeply rooted in our society. This growing concern is reflected in the strategies implemented by organizations, which are increasingly focused on ecofriendly strategies, not only for its strategic aspect but also for its social responsibility. Therefore, CaetanoBus and Toyota Caetano Portugal followed this trend by acting in an extremely important area, electric mobility. Since the market is becoming increasingly competitive in these areas it is necessary to ensure the ability of the organization to adapt to its volatility and the efficiency of its processes, in which logistics flows play an important role. It is in the scope of internal logistics flows and processes that this dissertation is involved, developed at Toyota Caetano Portugal´s plant in Ovar, in the electric chassis for buses production line. The main objective of this project is the optimization and improvement of logistics processes, using Lean tools. Firstly, a literature review was conducted to create a theoretical basis. Nest, it was necessary to perform a diagnosis and to map the current state of the logistics processes of the electric chassis line, in order to identify the existing problems and prioritize them in terms of urgency. After this diagnosis it was possible to conclude that the areas that needed immediate action due to their impact of logistics and production flows, were the picking operations, the supply of materials to the production line and the layout of the warehouse. Thus, based on the Lean philosophy and its inherent tools, such as Standard Work, 5S, Kaizen philosophy and Visual Management, several improvements were presented and implemented, to mitigate the problems that were previously identified. Regarding the picking operations, it was carried out the design of the picking boxes adapted to the second generation of chassis, as well as the study and conception of dollies suitable for this model and for the nature of the materials used in the production line. With the implementation of these improvements in the picking operations, more specifically the picking of the material for the picking boxes, a 44.6% reduction of the time spent on the operation was obtained. Due to the implementation of standard documents for these operations, the picking lists, it is estimated that the duration of this task may suffer an additional decrease of about 30%. When it comes to the supply of material to the production line, in addition to having achieved a reduction in the level of security risk of the operations, due to the implementation of a supply aisle and the use of appropriate means for the task, the duration of this logistic process was reduced by 18.4%. As for the layout of the warehouse, its sizing for two weeks of production, the application of an ABC Analysis and Visual Management tools resulted in the decrease of about 50% in the duration of the task of picking material from the general warehouse. This reduction has a great impact on the Takt Time of the internal logistics processes of the electric chassis line.
Nowadays, environmental concerns are deeply rooted in our society. This growing concern is reflected in the strategies implemented by organizations, which are increasingly focused on ecofriendly strategies, not only for its strategic aspect but also for its social responsibility. Therefore, CaetanoBus and Toyota Caetano Portugal followed this trend by acting in an extremely important area, electric mobility. Since the market is becoming increasingly competitive in these areas it is necessary to ensure the ability of the organization to adapt to its volatility and the efficiency of its processes, in which logistics flows play an important role. It is in the scope of internal logistics flows and processes that this dissertation is involved, developed at Toyota Caetano Portugal´s plant in Ovar, in the electric chassis for buses production line. The main objective of this project is the optimization and improvement of logistics processes, using Lean tools. Firstly, a literature review was conducted to create a theoretical basis. Nest, it was necessary to perform a diagnosis and to map the current state of the logistics processes of the electric chassis line, in order to identify the existing problems and prioritize them in terms of urgency. After this diagnosis it was possible to conclude that the areas that needed immediate action due to their impact of logistics and production flows, were the picking operations, the supply of materials to the production line and the layout of the warehouse. Thus, based on the Lean philosophy and its inherent tools, such as Standard Work, 5S, Kaizen philosophy and Visual Management, several improvements were presented and implemented, to mitigate the problems that were previously identified. Regarding the picking operations, it was carried out the design of the picking boxes adapted to the second generation of chassis, as well as the study and conception of dollies suitable for this model and for the nature of the materials used in the production line. With the implementation of these improvements in the picking operations, more specifically the picking of the material for the picking boxes, a 44.6% reduction of the time spent on the operation was obtained. Due to the implementation of standard documents for these operations, the picking lists, it is estimated that the duration of this task may suffer an additional decrease of about 30%. When it comes to the supply of material to the production line, in addition to having achieved a reduction in the level of security risk of the operations, due to the implementation of a supply aisle and the use of appropriate means for the task, the duration of this logistic process was reduced by 18.4%. As for the layout of the warehouse, its sizing for two weeks of production, the application of an ABC Analysis and Visual Management tools resulted in the decrease of about 50% in the duration of the task of picking material from the general warehouse. This reduction has a great impact on the Takt Time of the internal logistics processes of the electric chassis line.
Description
Keywords
Lean Picking Abastecimento Layout Armazenamento Mobilidade Elétrica Supply Warehousing Electric Mobility