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Publicação
MELHORIA CONTÍNUA: UM ESTUDO DE CASO NA INDÚSTRIA AERONÁUTICA
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Orientador(es)
Resumo(s)
As empresas do setor aeronáutico, à semelhança de empresas de outros setores
industriais, têm lidado com prazos de entrega cada vez mais curtos, falta de mão de obra
qualificada, requisitos de clientes cada vez mais exigentes, entre outros fatores que levam a
que as organizações sejam motivadas a melhorar os seus processos continuamente para obter
vantagem competitiva em relação aos seus concorrentes.
O presente estudo foi realizado na empresa OGMA S.A., uma organização focada na
fabricação de material aeronáutico e na manutenção de veículos aéreos e respetivos
componentes. O estudo em específico foi realizado na área de fabricação de aeroestruturas,
sendo o objetivo do projeto de melhoria continua a redução do tempo de ciclo de uma estação
pertencente a um processo de fabricação.
Ao longo do desenvolvimento do estudo, foram utilizadas diversas ferramentas
Lean
(
gemba walk, análise DNA, mapeamento do fluxo de valor, gestão visual, trabalho padronizado,poka-yoke) assim como outras ferramentas de apoio como o
brainstorming, a matriz de
flexibilidade, e quadro SQDC.
Foram desenvolvidas várias propostas de melhoria, tendo sido dado uma ênfase na
padronização do processo de fabrico que, devido à idade do programa, apresentava
deficiências no que toca à documentação técnica e procedimentos de produção.
Ao longo da implementação do plano de melhoria verificou-se uma diminuição em 28%
do tempo de ciclo da estação em estudo, assim como uma melhoria do estado de conservação
do posto de trabalho, com vista a mitigar riscos de segurança operacional existentes,
verificando-se a ocorrência de zero acidentes e incidentes desde a intervenção neste ponto.
Companies in the aeronautical sector, like companies in other industrial sectors, have been dealing with increasingly shorter delivery deadlines, lack of qualified labor, increasingly demanding customer requirements, among other factors that motivate organizations to continuously improve in order to gain competitive advantage over their competitors. This study was conducted at OGMA S.A., an organization focused on the manufacturing of aeronautical material and the maintenance of aircraft and their respective components. The specific study was carried out in aerostructure manufacturing, with the objective of the continuous improvement project being the reduction of cycle time of a station belonging to a manufacturing project. Throughout the development of the study, various Lean tools ( gemba walk, DNA analysis, value stream mapping, visual management, standardized work, poka-yoke) were used, as well as other analysis tools such as brainstorming, and visual management tools, such as the flexibility matrix and the SQDC board. Several improvement proposals were developed, with an emphasis on standardizing the manufacturing process which, due to the age of the program, had deficiencies regarding technical documentation and production procedures. Throughout the implementation of the improvement plan, there was a 28% decrease in the cycle time of the affected station, as well as an improvement in the state of conservation of the workstation, with a view to mitigating existing operational safety risks.
Companies in the aeronautical sector, like companies in other industrial sectors, have been dealing with increasingly shorter delivery deadlines, lack of qualified labor, increasingly demanding customer requirements, among other factors that motivate organizations to continuously improve in order to gain competitive advantage over their competitors. This study was conducted at OGMA S.A., an organization focused on the manufacturing of aeronautical material and the maintenance of aircraft and their respective components. The specific study was carried out in aerostructure manufacturing, with the objective of the continuous improvement project being the reduction of cycle time of a station belonging to a manufacturing project. Throughout the development of the study, various Lean tools ( gemba walk, DNA analysis, value stream mapping, visual management, standardized work, poka-yoke) were used, as well as other analysis tools such as brainstorming, and visual management tools, such as the flexibility matrix and the SQDC board. Several improvement proposals were developed, with an emphasis on standardizing the manufacturing process which, due to the age of the program, had deficiencies regarding technical documentation and production procedures. Throughout the implementation of the improvement plan, there was a 28% decrease in the cycle time of the affected station, as well as an improvement in the state of conservation of the workstation, with a view to mitigating existing operational safety risks.
Descrição
Palavras-chave
Fabricação de aeroestruturas Melhoria Contínua Lean Análise DNA Trabalho Padronizado Kaizen