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Identificação das Causas-Raízes de Sujidades de Verniz no Processo de Pintura da Volkswagen Autoeuropa
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Orientador(es)
Resumo(s)
O Grupo Volkswagen destaca-se no mercado automóvel pelos elevados padrões
de qualidade das suas marcas. De forma a manter a sua posição numa indústria extre-
mamente competitiva, é necessário assegurar a qualidade dos seus produtos, garantindo
a ausência de defeitos.
Um dos defeitos mais comuns no processo de pintura da Volkswagen Autoeuropa
são as sujidades de verniz, pelo que é extremamente relevante identificar as causas-raí-
zes para a sua ocorrência, bem como definir ações para que estas causas possam ser cor-
rigidas e controladas. É com esse intuito que surge a presente dissertação, após terem
sido detetadas oscilações do número de sujidades de verniz presentes nos automóveis.
De forma a identificar estas causas, foi realizada uma Análise dos Modos de Falha
e seus Efeitos (AMFE), tendo-se concluído que os modos de falha com prioridade de
atuação estão relacionados com as rotinas de limpeza das cabines de pintura, bem como
com a acumulação de verniz seco nas mangas de proteção dos robôs, por desregulação
do balanceamento das cabines.
Relativamente à acumulação de verniz seco, foram monitorizados os valores do
fluxo de ar nas cabines, tendo-se detetado irregularidades no crossdraft. Para corrigir este
problema, foram realizadas ações de limpeza, das quais resultou uma redução de 40%
das sujidades de verniz na totalidade de carros produzidos.
Foram também substituídas as mangas de proteção dos robôs atualmente utiliza-
das pois, apesar de não trazerem melhoria a nível de sujidades, originam uma poupança
semanal de 32,1%.
Quanto às rotinas de limpeza, foi criado um documento com a descrição passo a
passo de todas as tarefas, de forma a uniformizá-las. Foram também simplificadas e re-
estruturadas as atuais listas de verificação das tarefas realizadas.
Por fim, como forma de monitorização e controlo do processo, foram implementa-
das cartas de controlo para seis das cores de base atualmente pintadas.
The Volkswagen Group stands out in the automotive market for its brands' high- quality standards. To maintain its position in a highly competitive industry, it is neces- sary to ensure the quality of its products, by guaranteeing that they are free from defects. One of the most common defects in the paint process at Volkswagen Autoeuropa is clear coat dirt and dust, which makes it relevant to identify the root causes for the occurrence of this defect, as well as create prevention and control measurements. It is with that aim that this dissertation was elaborated, since there were fluctuations in the number of clear coat dirt and dust defects present in the vehicles. To identify the causes for this defect, a Failure Mode and Effect Analysis (FMEA) was conducted, which concluded that the failure modes with the priority of action were related to the spray booths' cleaning routines, as well as the accumulation of dry clear coat in the robots' protective covers, caused by an unregulated air balance. In terms of the accumulation of dry clear coat, the airflow parameters were moni- tored, which allowed the identification of crossflow irregularities. To correct this issue, cleaning actions were conducted, which resulted in a 40% reduction in clear coat dirt and dust in the total volume of vehicles produced. The protective robot sleeves currently in use were also replaced because, despite not contributing for the reduction of clear coat dirt and dust, this change results in a weekly saving of 32,1%. As for the cleaning routines, a document was elaborated with a step-by-step de- scription of all the tasks, to standardize them. The current checklist to verify the com- pleted task were also simplified and restructured. With the purpose of monitoring and controlling the painting process, control charts for six of the base coat colors were implemented.
The Volkswagen Group stands out in the automotive market for its brands' high- quality standards. To maintain its position in a highly competitive industry, it is neces- sary to ensure the quality of its products, by guaranteeing that they are free from defects. One of the most common defects in the paint process at Volkswagen Autoeuropa is clear coat dirt and dust, which makes it relevant to identify the root causes for the occurrence of this defect, as well as create prevention and control measurements. It is with that aim that this dissertation was elaborated, since there were fluctuations in the number of clear coat dirt and dust defects present in the vehicles. To identify the causes for this defect, a Failure Mode and Effect Analysis (FMEA) was conducted, which concluded that the failure modes with the priority of action were related to the spray booths' cleaning routines, as well as the accumulation of dry clear coat in the robots' protective covers, caused by an unregulated air balance. In terms of the accumulation of dry clear coat, the airflow parameters were moni- tored, which allowed the identification of crossflow irregularities. To correct this issue, cleaning actions were conducted, which resulted in a 40% reduction in clear coat dirt and dust in the total volume of vehicles produced. The protective robot sleeves currently in use were also replaced because, despite not contributing for the reduction of clear coat dirt and dust, this change results in a weekly saving of 32,1%. As for the cleaning routines, a document was elaborated with a step-by-step de- scription of all the tasks, to standardize them. The current checklist to verify the com- pleted task were also simplified and restructured. With the purpose of monitoring and controlling the painting process, control charts for six of the base coat colors were implemented.
Descrição
Palavras-chave
Verniz Sujidades Pintura Automóvel Volkswagen Melhoria