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Advisor(s)
Abstract(s)
A filosofia da Manutenção Produtiva Total (TPM), tem como principal objetivo melhorar a
qualidade, a produtividade e diminuir custos. Esta metodologia enquadra-se no envolvimento total
dos colaboradores, desde a produção até a gestão de topo, dando ênfase ao trabalho em equipa e
à conciliação operacional. Sendo assim, a implementação desta metodologia, possibilita a empresa
melhorar o desempenho nas intervenções de manutenção realizadas e, consequentemente, o
sistema de produção, tornando-se mais competitiva no seu mercado e aumentando os seus
rendimentos. O presente trabalho foi elaborado na empresa Super Bock Group, e assenta na
implementação da metodologia TPM numa linha de enchimento com vista ao aumento do
rendimento operacional da linha em questão, implementando metodologias Lean, com foco na
eliminação do desperdício e na procura pela melhoria contínua. Este objetivo visa diminuir as
avarias e aumentar a produtividade e eficiência operacional dos vários equipamentos. Para cumprir
com o objetivo traçado, foi necessário analisar as principais avarias, investigar quais os
equipamentos críticos da linha de produção, mentalizar os operadores referindo a importância da
manutenção autónoma, criar e melhorar os planos de manutenção preventiva.
Com a implementação da metodologia TPM, verificou-se o aumento do MTBF nos três ativos
críticos estudados e a diminuição do MTTR em dois deles, evidenciando uma diminuição da taxa de
avarias em dois dos equipamentos alvo do estudo efetuado, o ativo KISTERS com uma diminuição
de 1,3% e o ativo Enchedora com uma diminuição de 0,2%. Para esta redução contribuiu a
implementação da Manutenção Autónoma, bem como a criação e ajustes de planos de
manutenção preventiva. A Disponibilidade dos ativos estudados também melhorou, atingindo um
aumento de 2,6% no ativo KISTERS, e de 1% nos ativos Envolvedora e Enchedora.
Como desejado houve uma diminuição das intervenções corretivas, fazendo prevalecer as
intervenções de Manutenção Planeada. Assim, verificou-se uma diminuição das intervenções
corretivas em 18,3% e um aumento no caso das intervenções planeadas, de 13,5% na manutenção
preventiva sistemática e de 4,6% na manutenção corretiva planeada.
A implementação dos 6S e a identificação de desperdícios da manutenção também foi vital para a
obtenção de melhorias, melhor organização, eliminação de tempos de espera e diminuição de
custos.
A implementação da metodologia TPM e dos 6S, trouxe muitos benefícios para a linha alvo de
estudo, incluindo uma grande melhoria da segurança no ambiente de trabalho, aumento do
desempenho, qualidade e produtividade.
The philosophy of Total Productive Maintenance (TPM) has the main objective of improving quality, productivity and reducing costs. This methodology is based on the total involvement of employees, from production to top management, emphasising teamwork and operational conciliation. The implementation of this methodology enables the company to improve its performance in maintenance interventions and, consequently, the production system, making it more competitive in its market and increasing its income. This work was carried out at the Super Bock Group company and is based on the implementation of the TPM methodology on a filling line with a view to increasing the operational performance of the line in question, implementing Lean methodologies with a focus on eliminating waste and seeking continuous improvement. The aim is to reduce breakdowns and increase the productivity and operational efficiency of the various pieces of equipment. In order to achieve this goal, it was necessary to analyse the main breakdowns, investigate the critical equipment on the production line, get the operators thinking about the importance of autonomous maintenance, and create and improve preventive maintenance plans. With the implementation of the TPM methodology, there was an increase in MTBF in the three critical assets studied and a decrease in MTTR in two of them, showing a decrease in the breakdown rate in two of the pieces of equipment targeted in our study, the KISTERS with a decrease of 1,3% and the Filling Machine with a decrease of 0,2%. The implementation of Autonomous Maintenance contributed to this reduction, as did the creation and adjustment of preventive maintenance plans. The Availability of the assets studied also improved, reaching an increase of 2,6% at KISTERS, and 1% Wrapper and Filler. As desired, there was a decrease in corrective interventions, with Planned Maintenance interventions prevailing. Thus, there was a decrease in corrective interventions of 18,3 % and an increase in planned interventions of 13,5% in systematic preventive maintenance and 4.6 % in planned corrective maintenance. The implementation of 6S and the identification of maintenance waste was also vital in achieving improvements, better organisation, the elimination of waiting times and a reduction in costs. The implementation of the TPM methodology and 6S has brought many benefits to the line under study, including a major improvement in safety in the working environment, increased performance, quality and productivity.
The philosophy of Total Productive Maintenance (TPM) has the main objective of improving quality, productivity and reducing costs. This methodology is based on the total involvement of employees, from production to top management, emphasising teamwork and operational conciliation. The implementation of this methodology enables the company to improve its performance in maintenance interventions and, consequently, the production system, making it more competitive in its market and increasing its income. This work was carried out at the Super Bock Group company and is based on the implementation of the TPM methodology on a filling line with a view to increasing the operational performance of the line in question, implementing Lean methodologies with a focus on eliminating waste and seeking continuous improvement. The aim is to reduce breakdowns and increase the productivity and operational efficiency of the various pieces of equipment. In order to achieve this goal, it was necessary to analyse the main breakdowns, investigate the critical equipment on the production line, get the operators thinking about the importance of autonomous maintenance, and create and improve preventive maintenance plans. With the implementation of the TPM methodology, there was an increase in MTBF in the three critical assets studied and a decrease in MTTR in two of them, showing a decrease in the breakdown rate in two of the pieces of equipment targeted in our study, the KISTERS with a decrease of 1,3% and the Filling Machine with a decrease of 0,2%. The implementation of Autonomous Maintenance contributed to this reduction, as did the creation and adjustment of preventive maintenance plans. The Availability of the assets studied also improved, reaching an increase of 2,6% at KISTERS, and 1% Wrapper and Filler. As desired, there was a decrease in corrective interventions, with Planned Maintenance interventions prevailing. Thus, there was a decrease in corrective interventions of 18,3 % and an increase in planned interventions of 13,5% in systematic preventive maintenance and 4.6 % in planned corrective maintenance. The implementation of 6S and the identification of maintenance waste was also vital in achieving improvements, better organisation, the elimination of waiting times and a reduction in costs. The implementation of the TPM methodology and 6S has brought many benefits to the line under study, including a major improvement in safety in the working environment, increased performance, quality and productivity.
Description
Keywords
Preventive Maintenance Total Productive Maintenance (TPM) Autonomous Maintenance Lean Maintenance Performance Indicators