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Publicação
Melhoria do Indicador OEE em Linhas de Enchimento e Embalamento de Óleos e Azeites
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| 5.75 MB | Adobe PDF |
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Resumo(s)
A elevada pressão competitiva do setor alimentar, marcada por margens reduzidas e
elevada exigência de eficiência, torna essencial a adoção de metodologias que asseguram a
melhoria contínua dos processos produtivos.
Esta dissertação apresenta um estudo de caso sobre a aplicação da filosofia Kaizen e de
ferramentas Lean numa empresa portuguesa do setor de óleos e gorduras alimentares, no âmbito de um projeto desenvolvido em parceria com o Kaizen Institute. O estudo parte de dois
desafios centrais identificados na área de embalamento: os baixos níveis de Overall Equipment
Effectiveness (OEE) das linhas e a elevada variabilidade e imprevisibilidade dos tempos de se-
tup.
O estudo de caso incide em três linhas de produção. Numa linha automática aplica-se a
metodologia SMED, que permitiu reduzir o tempo de setup em 50 por cento, correspondendo
a cerca de 10 horas de capacidade libertada num único mês. Numa linha semi-automática
aplica-se Standard Work, medida que possibilitou aumentar a capacidade produtiva e resultou
num acréscimo de 9 pontos percentuais no OEE. Noutra linha semi-automática propõe-se a
reorganização em layout em U com recurso ao Simplified Systematic Layout Planning, que projetou uma redução de 37,5 por cento na distância percorrida por palete, aumentando a fluidez
do processo e diminuindo os movimentos do operador.
Os resultados obtidos demonstram que a integração estruturada de práticas Lean nesta
indústria contribui de forma significativa para o aumento do OEE e para a consolidação de
uma cultura de melhoria contínua, assegurando ganhos imediatos e sustentáveis no longo
prazo.
The high competitive pressure within the food sector, characterized by low margins and a strong demand for efficiency, makes the adoption of methodologies that ensure the continuous improvement of production processes essential. This dissertation presents a case study on the application of the Kaizen philosophy and Lean tools in a Portuguese company operating in the edible oils and fats sector, developed in partnership with the Kaizen Institute. The study addresses two central challenges identified in the packaging area: the low levels of Overall Equipment Effectiveness (OEE) and the high variability and unpredictability of setup times. The case study focuses on three production lines. On an automatic line, the SMED methodology was applied, enabling a 50 percent reduction in setup time, which corresponds to approximately 10 hours of additional capacity released in a single month. On a semi-automatic line, Standard Work was introduced, which increased productive capacity and led to a 9-percentage-point improvement in OEE. On another semi-automatic line, a U-shaped layout was proposed using Simplified Systematic Layout Planning, projecting a 37.5 percent reduction in the distance traveled per pallet, thereby enhancing process flow and reducing operator movements. The results demonstrate that the structured integration of Lean practices in this industry contributes significantly to improving OEE and consolidating a culture of continuous im- provement, ensuring both immediate and sustainable long-term gains.
The high competitive pressure within the food sector, characterized by low margins and a strong demand for efficiency, makes the adoption of methodologies that ensure the continuous improvement of production processes essential. This dissertation presents a case study on the application of the Kaizen philosophy and Lean tools in a Portuguese company operating in the edible oils and fats sector, developed in partnership with the Kaizen Institute. The study addresses two central challenges identified in the packaging area: the low levels of Overall Equipment Effectiveness (OEE) and the high variability and unpredictability of setup times. The case study focuses on three production lines. On an automatic line, the SMED methodology was applied, enabling a 50 percent reduction in setup time, which corresponds to approximately 10 hours of additional capacity released in a single month. On a semi-automatic line, Standard Work was introduced, which increased productive capacity and led to a 9-percentage-point improvement in OEE. On another semi-automatic line, a U-shaped layout was proposed using Simplified Systematic Layout Planning, projecting a 37.5 percent reduction in the distance traveled per pallet, thereby enhancing process flow and reducing operator movements. The results demonstrate that the structured integration of Lean practices in this industry contributes significantly to improving OEE and consolidating a culture of continuous im- provement, ensuring both immediate and sustainable long-term gains.
Descrição
Palavras-chave
Lean Kaizen OEE SMED Standard Work SSLP