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Abstract(s)
A indústria automóvel tem-se imposto cada vez mais como um dos principais pilares da economia à escala global. A globalização dos meios de transporte, quer públicos quer pessoais, exigiu a produção de veículos e componentes a larga escala, através da produção em massa e a preços reduzidos, sem comprometer a qualidade do produto num meio cada vez mais competitivo. Para se conseguir esse equilíbrio, é necessária a melhoria contínua e otimização dos processos e produtos nas empresas do ramo automóvel. A exigência por parte do cliente é cada vez maior, sendo necessário aumentar o número de pedidos e reduzir os prazos de entrega. Todas estas alterações levam a que os procedimentos utilizados outrora, estejam atualmente ultrapassados e seja necessária a inovação. No entanto, não é viável reagir ao primeiro impulso de aumentar a mão de obra ou as linhas de produção sem melhorar e otimizar os processos existentes. É neste contexto que se enquadra a presente dissertação: analisando o seu processo de estampagem, a Gestamp Aveiro, Indústria de Acessórios Automóveis, S.A. verificou que certas ferramentas apresentam baixo overall equipment effectiveness (OEE), pretendendo diminuir o tempo de setup e tempo de paragens de produção através da modificação do seu sistema transfer. O projeto de melhoria dos processos inerentes ao sistema transfer de uma ferramenta engloba diversas áreas. Foram aplicadas váriasferramentas de gestão, tal como a Failure mode and effects analysis (análise FMEA) na fase pré-projeto. Foi pensado um novo conceito para o transfer, de forma a aumentar a estabilidade do mesmo. De forma a melhorar a fiabilidade da manutenção preventiva dos sistemas transfer, foi criada e implementada uma instrução de trabalho para esta tarefa. Os resultados do trabalho desenvolvido na presente dissertação permitiram compreender as alterações no rendimento da ferramenta em causa após a alteração do sistema transfer. Assim, a empresa deverá avaliar a implementação deste novo conceito nas restantes ferramentas do tipo transfer.
The automotive industry has increasingly established itself as one of the main pillars of the economy at a global scale. The globalization of means of transport, both public and personal, required the production of vehicles and components at a large scale, through mass production and at low prices, without compromising the quality of the product in an increasingly competitive industry. To achieve this balance, a continuous improvement and optimization of processes and products in automotive companies are necessary. The costumers’ demand is growing, making it necessary to increase the number of orders and reduce deadlines. All these changes showed that the processes used in the past are outdated and innovation is needed. Nonetheless, it is not viable to react to a first impulse and increase manpower or production lines without improving and optimizing the existing processes. It is in this context that the present dissertation emerges: analyzing its stamping process, Gestamp Aveiro, Indústria de Acessórios Automóveis, S.A. found that certain transfer dies have low overall equipment effectiveness(OEE), and aimed at the modification of the transfer system, to decrease the setup time and production stoppage. The project to improve the inherent processes to the transfer system of a stamping die includes several areas. Several management tools were applied, such as Failure mode and effects analysis (FMEA analysis) in the pre-project phase. A new concept was devised for the transfer system to increase its stability. A work instruction was created and implemented with the purpose of improving preventive maintenance of transfer systems reliability. The results of the work developed in this dissertation allowed an understanding of the changes in the performance of the die under analysis, after changing the transfer system. Therefore, the company should evaluate the implementation of this new concept in the remaining transfer dies.
The automotive industry has increasingly established itself as one of the main pillars of the economy at a global scale. The globalization of means of transport, both public and personal, required the production of vehicles and components at a large scale, through mass production and at low prices, without compromising the quality of the product in an increasingly competitive industry. To achieve this balance, a continuous improvement and optimization of processes and products in automotive companies are necessary. The costumers’ demand is growing, making it necessary to increase the number of orders and reduce deadlines. All these changes showed that the processes used in the past are outdated and innovation is needed. Nonetheless, it is not viable to react to a first impulse and increase manpower or production lines without improving and optimizing the existing processes. It is in this context that the present dissertation emerges: analyzing its stamping process, Gestamp Aveiro, Indústria de Acessórios Automóveis, S.A. found that certain transfer dies have low overall equipment effectiveness(OEE), and aimed at the modification of the transfer system, to decrease the setup time and production stoppage. The project to improve the inherent processes to the transfer system of a stamping die includes several areas. Several management tools were applied, such as Failure mode and effects analysis (FMEA analysis) in the pre-project phase. A new concept was devised for the transfer system to increase its stability. A work instruction was created and implemented with the purpose of improving preventive maintenance of transfer systems reliability. The results of the work developed in this dissertation allowed an understanding of the changes in the performance of the die under analysis, after changing the transfer system. Therefore, the company should evaluate the implementation of this new concept in the remaining transfer dies.
Description
Keywords
Componentes automóveis Estampagem Melhoria de processo Projeto mecânico Sistema transfer Automotive components Stamping Process optimization Mechanical design Transfer system