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Abstract(s)
As empresas de produção de mobiliário enfrentam diversos obstáculos num mercado
competitivo que tem vindo a crescer exponencialmente. O aumento do custo dos materiais, a
variação na procura, a pressão para entregar produtos com elevada qualidade a preços
reduzidos e a constante mudança de preferências dos consumidores são algumas das razões
que fazem com que as empresas deste ramo sintam a necessidade de se adaptar rapidamente
aos novos designs e tendências, o que pode ser difícil quando o sistema produtivo não é flexível.
A crescente preocupação pelo meio ambiente e a demanda por produtos e processos com
menos desperdícios obriga as indústrias a aplicarem métodos de produção mais sustentáveis,
enquanto mantém margens de lucro e elevados níveis de produtividade.
Esta dissertação, desenvolvida em contexto de estágio na Ferluca – Mecânica, Lda., teve como
foco a otimização do sistema produtivo da organização e da eficiência global, a redução de
desperdícios e o aumento da produtividade. A análise das linhas de produção de dois produtos
diferentes permitiu identificar postos com efeito de gargalo, bottlenecks, tempos excessivos de
transporte entre estações de trabalho e tempos de setup das diferentes operações demasiado
longos.
O melhoramento do layout do chão de fábrica através do posicionamento estratégico dos
equipamentos, postos de trabalho e locais de armazenamento, permitiu simplificar o fluxo dos
materiais e componentes ao longo da produção, eliminando movimentos desnecessários,
alcançando uma redução de cerca de 31% dos tempos de transporte, reduzindo o lead time do
sistema produtivo.
A implementação de ferramentas Lean, com especial destaque à metodologia SMED, permitiu
obter uma redução de cerca de 29% dos tempos de setup das linhas de produção por meio da
identificação e conversão de algumas atividades internas em atividades externas das tarefas de
setup, o que contribuiu para um aumento da flexibilidade e produtividade da organização.
No geral, as expectativas para este estudo foram superadas e foi demonstrado que a otimização
de um sistema produtivo e a implementação de ferramentas e técnicas Lean tem impacto
positivo na eficiência global de uma organização. Além disso, os resultados obtidos não só
comprovam o aumento de produtividade, mas são também dados importantes para a
realização de trabalhos futuros.
The furniture production factories face multiple challenges in a competitive market that has been growing exponentially. The rise of the costs of the materials, the variation of the demand, the pressure to deliver products with high quality at low prices and the constant change of preferences of the consumers are a few of the reasons that make the companies in this field the need to adapt quickly to the new designs and tendencies, which can be difficult when the production system is not flexible. The growing concern for the environment and the demand for products and processes with less waste forces industries to apply more sustainable production methods, while maintaining profit margins and high levels of productivity. This thesis, developed in an internship context in Ferluca – Mecânica, Lda., focused on the optimization of the production system of the organization and the global efficiency, the reduction of wastes and the increase in productivity. The analysis of the production lines of two different products allowed the identification of bottleneck stations, excessive times of transportation between workstations and setup times for different operations take too long. The improvement of the factory layout through strategic positioning of equipment, workstations and storage locations, allowed to simplify the flow of materials and components throughout the production, eliminating unnecessary movements, achieving a reduction of approximately 31% in the transportation times, thereby reducing the lead time of the production system. The implementation of Lean tools, with particular emphasis on the SMED methodology, which allowed to achieve a reduction of approximately 29% in setup times for production lines through the identification and conversion of some internal activities to external activities of the setup tasks, which contributed to an increase in flexibility and productivity of the organization. In general, the expectations for this study were overachieved and it was demonstrated that the optimization of a production system and the implementation of Lean tools and techniques has a positive impact in the global efficiency of an organization. Furthermore, the results obtained not only demonstrate the increase in productivity but also provide important data for future work.
The furniture production factories face multiple challenges in a competitive market that has been growing exponentially. The rise of the costs of the materials, the variation of the demand, the pressure to deliver products with high quality at low prices and the constant change of preferences of the consumers are a few of the reasons that make the companies in this field the need to adapt quickly to the new designs and tendencies, which can be difficult when the production system is not flexible. The growing concern for the environment and the demand for products and processes with less waste forces industries to apply more sustainable production methods, while maintaining profit margins and high levels of productivity. This thesis, developed in an internship context in Ferluca – Mecânica, Lda., focused on the optimization of the production system of the organization and the global efficiency, the reduction of wastes and the increase in productivity. The analysis of the production lines of two different products allowed the identification of bottleneck stations, excessive times of transportation between workstations and setup times for different operations take too long. The improvement of the factory layout through strategic positioning of equipment, workstations and storage locations, allowed to simplify the flow of materials and components throughout the production, eliminating unnecessary movements, achieving a reduction of approximately 31% in the transportation times, thereby reducing the lead time of the production system. The implementation of Lean tools, with particular emphasis on the SMED methodology, which allowed to achieve a reduction of approximately 29% in setup times for production lines through the identification and conversion of some internal activities to external activities of the setup tasks, which contributed to an increase in flexibility and productivity of the organization. In general, the expectations for this study were overachieved and it was demonstrated that the optimization of a production system and the implementation of Lean tools and techniques has a positive impact in the global efficiency of an organization. Furthermore, the results obtained not only demonstrate the increase in productivity but also provide important data for future work.
Description
Keywords
Furniture industry Lean Layout optimization SMED Improvement of the production system Indústria do mobiliário Otimização do layout Melhoria do sistema produtivo