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Aumento da Eficiência de uma Linha de Embalagem numa Indústria de Papel
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Ao longo das últimas décadas, as empresas têm vindo a aplicar práticas
Lean nos seus
processos, com o objetivo de aumentar a eficiência dos mesmos. Na indústria do papel, o Lean
desempenha um papel crucial devido às características específicas desse setor. Esta indústria
pode gerar uma quantidade significativa de desperdícios, incluindo resíduos de matérias-pri-
mas, energia e tempo. O Lean ajuda a identificar e eliminar esses desperdícios, resultando em
uma produção mais eficiente e económica. A The Navigator Company é uma das maiores em-
presas produtoras de papel do mundo e destaca-se pela aplicação consistente e bem-sucedida
de várias ferramentas Lean ao longo dos anos. Essas iniciativas visam melhorar continuamente
os seus processos internos e aumentar a eficiência operacional. Nesse âmbito surgiu este pro-
jeto com o objetivo de melhorar o processo
Cut-Size, procurando maximizar a produção de
paletes por unidade de tempo, reduzindo para isso os tempos de paragem da linha. Para a
realização do estudo foram utilizadas várias ferramentas analíticas do
Lean, tais como VSM,
Quadros
Kaizen, Cartões
Kamishibai,
SMED, 5S, entre outras. Também foram aplicadas algumas
ferramentas da gestão de qualidade como Diagrama de Pareto, 5
Why's, Diagrama de Causa-
Efeito, entre outras. Foram identificadas sete oportunidades de melhoria no processo em es-
tudo, para as quais foram desenvolvidas sete propostas. A renovação de Quadros
Kaizen já
existentes e a introdução de Cartões
Kamishibai para controlo das reuniões diárias foram pro-
postas que permitiram obter melhores indicadores de desempenho e melhor diagnóstico das
dificuldades. O restabelecimento da cadência de produção, a implementação de um
buffer de segurança e a redução dos tempos de
set-up possibilitaram o indicador de Eficiência Tempo
chegar aos 87.47% e o indicador Global aos 85.05%. Verificou-se ainda uma redução de custos
de 55.6% com a solução dos problemas de escorregamento de mandris.
Over the last few decades, companies have been applying Lean practices to their pro- cesses in order to increase their efficiency. In the paper industry, Lean plays a crucial role due to the specific characteristics of this sector. This industry can generate a significant amount of waste, including waste raw materials, energy and time. Lean helps to identify and eliminate this waste, resulting in more efficient and economical production. The Navigator Company is one of the largest paper producers in the world and stands out for its consistent and successful application of various Lean tools over the years. These initiatives aim to continuously improve its internal processes and increase operational efficiency. In this context, this project was set up with the aim of improving the Cut-Size process, seeking to maximize the production of pallets per unit of time, thereby reducing line downtime. To carry out the study, various Lean analytical tools were used, such as VSM, Kaizen Boards, Kamishibai Cards, SMED, 5S, among others. Some quality management tools were also applied, such as the Pareto Diagram, the 5 Why's, the Cause-Effect Diagram, among others. Seven opportunities for improvement were identified in the process under study, for which seven proposals were developed. The renewal of existing Kaizen Boards and the introduction of Kamishibai Cards to control daily meetings were proposals that made it possible to obtain better performance indicators and a better diagnosis of difficulties. Restoring the production cadence, implementing a safety buffer, and reducing set-up times enabled the Time Efficiency indicator to reach 87.47% and the Overall indicator to reach 85.05%. There was also a reduction of 55.6% in costs as result of the solution to spindle slippage problems.
Over the last few decades, companies have been applying Lean practices to their pro- cesses in order to increase their efficiency. In the paper industry, Lean plays a crucial role due to the specific characteristics of this sector. This industry can generate a significant amount of waste, including waste raw materials, energy and time. Lean helps to identify and eliminate this waste, resulting in more efficient and economical production. The Navigator Company is one of the largest paper producers in the world and stands out for its consistent and successful application of various Lean tools over the years. These initiatives aim to continuously improve its internal processes and increase operational efficiency. In this context, this project was set up with the aim of improving the Cut-Size process, seeking to maximize the production of pallets per unit of time, thereby reducing line downtime. To carry out the study, various Lean analytical tools were used, such as VSM, Kaizen Boards, Kamishibai Cards, SMED, 5S, among others. Some quality management tools were also applied, such as the Pareto Diagram, the 5 Why's, the Cause-Effect Diagram, among others. Seven opportunities for improvement were identified in the process under study, for which seven proposals were developed. The renewal of existing Kaizen Boards and the introduction of Kamishibai Cards to control daily meetings were proposals that made it possible to obtain better performance indicators and a better diagnosis of difficulties. Restoring the production cadence, implementing a safety buffer, and reducing set-up times enabled the Time Efficiency indicator to reach 87.47% and the Overall indicator to reach 85.05%. There was also a reduction of 55.6% in costs as result of the solution to spindle slippage problems.
Descrição
Palavras-chave
Lean Eficiência dos Processos Kaizen Melhoria Contínua Kamishibai Redução de Downtimes