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Abstract(s)
Este trabalho foi desenvolvido em uma indústria automóvel multinacional japonesa, na fábrica de
Portugal, com o objetivo de otimização do processo de conetores airbag 90°, designados por SQUIB,
e de eliminar uma inspeção após processo produtivo, designada por firewall, que impacta os custos
de não qualidade, problemas de entrega, atingindo a sustentabilidade e que diretamente irá
aumentar os níveis de qualidade e satisfação dos clientes. Poderemos reduzir ou eliminar processos
não planeados através da análise DMAIC? Com a concorrência cada vez mais acirrada e clientes
cada vez mais exigentes, as empresas precisam estar focadas na sustentabilidade financeira, para
se manterem competitivas e se adequarem às necessidades do mercado que terá também impacto
na sustentabilidade ambiental. Para tal é necessário ter foco na resolução de problemas e
consecutiva melhoria contínua, pois é o principal pilar para tornar toda e qualquer empresa
rentável. Através da metologia DMAIC, recorrendo a ferramentas como o Project Charter,
fluxograma de processo, FMEA, Diagrama de Ishikawa, Diagrama de Pareto, 5 porquês entre outras
ferramentas, foi possível irradicar o defeito principal, passando de uma média de 11 000 PPM para
0 PPM. O defeito de laser era responsável por mais de 80% dos defeitos detetados na firewall,
eliminando um desperfício médio mensal de 6358 de conectores de SQUIB devido à falha de laser,
com um impacto médio mensal de 2 mil euros. Quando forem finalizadas todas as acções
planeadas, e tendo por base os onze meses deste caso de estudo, haverá um impacto financeiro de
mais de 50 mil euros, uma redução de desperdício de 400 quilogramas de material plástico e
metálico ferroso e um ganho direto de 300 euros em energia elétrica eliminando a necessidade de
produzir uma segunda vez.
This work was developed in a Japanese multinational automobile industry, at the factory in Portugal, with the objective of optimizing the process of 90° airbag connectors, called SQUIB, and eliminating an inspection after the production process, called firewall, which impacts non-quality costs, delivery problems, reaching the sustainability and which will directly increase quality levels and customer satisfaction. Can we reduce or eliminate unplanned processes through DMAIC analysis? With competition becoming growth fierce and customers increasingly demanding, companies need to be focused on financial sustainability, to remain competitive and adapt to market needs, which will also have an impact on environmental sustainability. To do this, it is necessary to focus on problem solving and consecutive continuous improvement, as it is the main pillar to make any company profitable. Through the DMAIC methodology, using tools such as the project charter, process flowchart, FMEA, Ishikawa diagram, Pareto diagram, 5 Why’s among other tools, it was possible to eradicate the main defect, going from an average of 11000 PPM to 0 PPM. The laser defect was responsible for more than 80% of the defects detected in the firewall, eliminating an average waste 6358 SQUIB connectors per month due to laser failure, with an average monthly impact of 2 thousand euros. Upon completion of all planned actions and based on the eleven months of this case study, there will be a financial impact of more than 50 thousand euros, a reduction in waste of 400 kilograms of plastic and ferrous metal material and a direct gain of 300 euros in electrical energy eliminating the need to produce a second time.
This work was developed in a Japanese multinational automobile industry, at the factory in Portugal, with the objective of optimizing the process of 90° airbag connectors, called SQUIB, and eliminating an inspection after the production process, called firewall, which impacts non-quality costs, delivery problems, reaching the sustainability and which will directly increase quality levels and customer satisfaction. Can we reduce or eliminate unplanned processes through DMAIC analysis? With competition becoming growth fierce and customers increasingly demanding, companies need to be focused on financial sustainability, to remain competitive and adapt to market needs, which will also have an impact on environmental sustainability. To do this, it is necessary to focus on problem solving and consecutive continuous improvement, as it is the main pillar to make any company profitable. Through the DMAIC methodology, using tools such as the project charter, process flowchart, FMEA, Ishikawa diagram, Pareto diagram, 5 Why’s among other tools, it was possible to eradicate the main defect, going from an average of 11000 PPM to 0 PPM. The laser defect was responsible for more than 80% of the defects detected in the firewall, eliminating an average waste 6358 SQUIB connectors per month due to laser failure, with an average monthly impact of 2 thousand euros. Upon completion of all planned actions and based on the eleven months of this case study, there will be a financial impact of more than 50 thousand euros, a reduction in waste of 400 kilograms of plastic and ferrous metal material and a direct gain of 300 euros in electrical energy eliminating the need to produce a second time.
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Keywords
Six Sigma DMAIC Automotive Industry Problem Solving Sustainability