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Otimização do processo produtivo de extrusão de pisos na E06
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Advisor(s)
Abstract(s)
O presente trabalho foi elaborado no âmbito da Dissertação Final de Mestrado do curso de
Engenharia Mecânica – Gestão Industrial do Instituto Superior de Engenharia do Porto. Este
foi realizado numa empresa da indústria de pneus, a Continental Mabor S.A..
Nos dias atuais, a indústria esta cada vez mais competitiva, os custos e os prazos da entrega são
cada vez mais reduzidos e a qualidade cada vez mais exigente, assim sendo, é imprescindível
uma constante melhoria do sistema produtivo.
Este fato fez com que o presente trabalho tivesse como principal objetivo determinar o estado
atual e delinear um plano de melhoria para um equipamento (Extrusora de pisos nº6),
recentemente instalado na fábrica mas oriundo de outra fábrica do grupo, recorrendo para tal
ao Lean Manufacturing e a ferramentas que lhe estão associadas.
Inicialmente realizou-se uma análise e diagnóstico ao processo de extrusão de pisos na
Extrusora nº6, com o intuito de avaliar todas as suas ineficiências e ainda formular um plano
de melhorias para a ineficiência de maior impacto no sistema produtivo. Esta análise foi
realizada em diferentes turnos e diferentes equipas de trabalho de forma a se obter uma
amostra mais representativa da realidade global.
Após esta análise verificou-se que as principais ineficiências eram Setup, conformidade do
material, dimensões e encravamentos, entre outros. Sendo que os Setup provocam um tempo
de paragem de 101 minutos por turno, escolheu-se esta perturbação como o foco do plano de
melhorias a realizar posteriormente.
De forma a reduzir os tempos de mudança (Setup), o autor no presente trabalho utilizou
ferramentas Lean Manufacturing, principalmente o SMED. Conjuntamente com o SMED ainda
foram utilizadas outras ferramentas Lean Manufacturing tais como: 5S, Gestão Visual,
Problem Solving e Normalização do Método de Trabalho.
Após a implementação de todas estas ferramentas obteve-se uma redução de tempos de
mudança de 43% com 1 operador e 71% com 2 operadores, ou seja, reduziu-se de 40,5 minutos
gastos por turno para a mudança de fieira para 23,13 min e 11,79 min respetivamente, o que
corresponde a um ganho monetário anual de 63.621€ ou 105.045€, respetivamente. Com este trabalho conclui-se que a utilização de ferramentas Lean Manufacturing contribuem
para a redução dos desperdícios do processo produtivo. Por isso, espera-se que este estudo seja
aplicado na Extrusora nº6 e nas restantes Extrusoras de pisos existentes na fábrica, e num
futuro próximo que se realize estudos semelhantes em máquinas com diferentes funções.
The present dissertation was prepared under the Final Masters Course of Mechanical Engineering - Industrial Management from the Instituto Superior de Engenharia do Porto. All the mains tasks of this thesis were prepared in an industrial environment, more precisely in Continental Mabor S.A. tire plant. Nowadays industry is getting more and more competitive, costs must be reduced to a minimum, delivery dates are getting shorter and, on the other hand, the necessity of a high quality level is increasing every day. Being it so, and in order to tackle this, a daily processes’ continuous improvement is required. All the above mentioned premises were the key elements for preparing a dissertation that, based in the Lean Manufacturing concepts and associated tools, had as main goal the determination of the actual status of a transferred equipment from a different plant and, at the same time, the preparation of a respective action plan for that same machine: the tread extruder number 6. The work started with a diagnosis and analysis of the tread extrusion process in extruder machine number 6, with the goal of identifying and evaluating all the inefficiencies, so that an action plan could be determined in order to improve the productive system. As a remark, the diagnosis was done in different shifts and teams so that the sample was as close to real as possible. After this first step it was possible to realize that the main inefficiencies were resulting from different causes, such as set-ups, non-conforming material and wrong tolerances, among others. Once the set-ups have a major impact on production level (more precisely time losses of around 101 minutes per shift), this reason was chosen as the main cause and the focus of the action plan to be done and worked afterwards. In order to reduce the set-up time losses, the author used as already referred the Lean Manufacturing tools, more precisely the SMED – Single Minute Exchange Dies. It was also used some more Lean Manufacturing tools such as: the 5´s, visual management, problem solving and work methods standardization. After the implementation of all these tools it was possible to achieve a time reduction of 43% with one operator and 71% with two operators, passing from around 40,5 minutes per shift to 23,13 minutes with one operator and 11,79 minutes for two operators, representing this a saving of 63.621€/year working with one operator and 105.045€/year working with two operators.
The present dissertation was prepared under the Final Masters Course of Mechanical Engineering - Industrial Management from the Instituto Superior de Engenharia do Porto. All the mains tasks of this thesis were prepared in an industrial environment, more precisely in Continental Mabor S.A. tire plant. Nowadays industry is getting more and more competitive, costs must be reduced to a minimum, delivery dates are getting shorter and, on the other hand, the necessity of a high quality level is increasing every day. Being it so, and in order to tackle this, a daily processes’ continuous improvement is required. All the above mentioned premises were the key elements for preparing a dissertation that, based in the Lean Manufacturing concepts and associated tools, had as main goal the determination of the actual status of a transferred equipment from a different plant and, at the same time, the preparation of a respective action plan for that same machine: the tread extruder number 6. The work started with a diagnosis and analysis of the tread extrusion process in extruder machine number 6, with the goal of identifying and evaluating all the inefficiencies, so that an action plan could be determined in order to improve the productive system. As a remark, the diagnosis was done in different shifts and teams so that the sample was as close to real as possible. After this first step it was possible to realize that the main inefficiencies were resulting from different causes, such as set-ups, non-conforming material and wrong tolerances, among others. Once the set-ups have a major impact on production level (more precisely time losses of around 101 minutes per shift), this reason was chosen as the main cause and the focus of the action plan to be done and worked afterwards. In order to reduce the set-up time losses, the author used as already referred the Lean Manufacturing tools, more precisely the SMED – Single Minute Exchange Dies. It was also used some more Lean Manufacturing tools such as: the 5´s, visual management, problem solving and work methods standardization. After the implementation of all these tools it was possible to achieve a time reduction of 43% with one operator and 71% with two operators, passing from around 40,5 minutes per shift to 23,13 minutes with one operator and 11,79 minutes for two operators, representing this a saving of 63.621€/year working with one operator and 105.045€/year working with two operators.
Description
Keywords
Setup SMED Lean Manufacturing Extrusão de pisos Melhoria contínua Tread extrusion Continuous improvement
Pedagogical Context
Citation
Publisher
Instituto Politécnico do Porto. Instituto Superior de Engenharia do Porto