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Melhoria de uma linha de produção de discos agrícolas recorrendo a metodologias Lean
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Ao longo dos anos as indústrias têm vivenciado um crescimento significativo despole-
tado por diversos fatores como, os avanços tecnológicos, a globalização, as mudanças de pre-
ferências dos consumidores, entre outros. A elevada competição que este crescimento trouxe
para as indústrias, leva a que as indústrias procurem estar na vanguarda da tecnologia e utilizar
métodos inovadores que permitam melhorar os seus processos de forma a entregar um pro-
duto cada vez mais customizado e de maior qualidade.
Este estudo de caso consiste na análise e proposta de melhoria para uma linha de pro-
dução de uma unidade industrial. Para identificar qual a linha a que se destinaria este estudo,
iniciou-se por analisar as horas de trabalho de cada linha e realizaram-se diversos
Gemba
Walks, que permitiram identificar a linha de produção de discos como a mais crítica. Após a
identificação da linha, e com recurso a ferramentas
Lean, foram identificados os problemas da
linha sendo eles o elevado de tempo de ciclo da operação de biselar, a falta de marcação de
espaços, a falta de locais específicos para arrumação de moldes, retrocessos na linha de pro-
dução e ainda a falta de um plano de manutenção e limpeza.
Com os problemas identificados, procedeu-se à definição das propostas de melhoria,
tendo proposto a aquisição de um robot para a substituição dos operadores na operação de
biselar assim como na operação de furação e estampagem. A implementação deste robô per-
mitirá uma redução do tempo de ciclo na ordem dos 30% e com o novo layout resultante da
implementação do mesmo, será possível reduzir a distância percorrida cerca de 28% para a
produção de discos lisos e 53% para os discos recortados. Em relação aos outros problemas
foram definidos planos de ação que permitiram melhorar a eficiência dos processos, assim
como na manutenção de um local de trabalho limpo e organizado.
Over the years, industries have experienced significant growth triggered by various fac- tors such as technological advances, globalisation, changing consumer preferences, among others. The high level of competition that this growth has brought to industries has led them to seek to be at the forefront of technology and use innovative methods to improve their processes in order to deliver an increasingly customised and higher quality product. This case study consists of analysing and proposing improvements to a production line in an industrial unit. In order to identify which, line this study would focus on, we began by analysing the working hours of each line and carried out several Gemba Walks, which enabled us to identify the disc production line as the most critical. After identifying the line, and using Lean tools, the line's problems were identified, including the high cycle time of the bevelling operation, the lack of space marking, the lack of specific places to store moulds, setbacks on the production line and the lack of a maintenance and cleaning plan. Once the problems had been identified, the proposals for improvement were defined and the purchase of a robot was proposed to replace the operators in the bevelling operation as well as in the drilling and stamping operation. The implementation of this robot will allow a decrease in cycle time of 30% and with the new layout resulting from its implementation, it will be possible to reduce the distance travelled by around 28% to produce plain discs and 53% for sliced discs. About the other problems, action plans were defined to improve process effi- ciency, as well as maintaining a clean and organised workplace.
Over the years, industries have experienced significant growth triggered by various fac- tors such as technological advances, globalisation, changing consumer preferences, among others. The high level of competition that this growth has brought to industries has led them to seek to be at the forefront of technology and use innovative methods to improve their processes in order to deliver an increasingly customised and higher quality product. This case study consists of analysing and proposing improvements to a production line in an industrial unit. In order to identify which, line this study would focus on, we began by analysing the working hours of each line and carried out several Gemba Walks, which enabled us to identify the disc production line as the most critical. After identifying the line, and using Lean tools, the line's problems were identified, including the high cycle time of the bevelling operation, the lack of space marking, the lack of specific places to store moulds, setbacks on the production line and the lack of a maintenance and cleaning plan. Once the problems had been identified, the proposals for improvement were defined and the purchase of a robot was proposed to replace the operators in the bevelling operation as well as in the drilling and stamping operation. The implementation of this robot will allow a decrease in cycle time of 30% and with the new layout resulting from its implementation, it will be possible to reduce the distance travelled by around 28% to produce plain discs and 53% for sliced discs. About the other problems, action plans were defined to improve process effi- ciency, as well as maintaining a clean and organised workplace.
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Lean Indústria metalomecânica VSM Diagrama de esparguete Robôs