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Redução dos tempos de setup aplicada a uma linha de embalagem
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A indústria farmacêutica ao longo do tempo, em Portugal, tem aumentado as suas ven-das por ano. Com este crescimento, as empresas sentem a necessidade de aumentar a sua produtividade.
Este estudo foi desenvolvido numa linha de embalagem de uma empresa farmacêutica, com o objetivo de reduzir os tempos de setup. A redução dos tempos de setup permite reduzir os tempos não produtivos e assim aumentar a produtividade de uma fábrica.
A metodologia de trabalho seguida neste estudo, começa com a compreensão do estado inicial dos setups na linha de embalagem, através de uma recolha e análise de dados dos tem-pos de setup. De seguida, são apresentadas as melhorias implementadas na linha de embala-gem e os resultados que advêm destas melhorias. Por fim, são descritas melhorias que ainda podem ser implementadas de forma a alcançar melhores resultados.
De forma a suportar o desenvolvimento deste trabalho foi aplicado um relatório A3 e diversas ferramentas de apoio, relacionadas com a filosofia Lean, tais como: SMED, ciclo PDCA, 5S, diagrama de Gantt, recolha de tempos, gestão visual, trabalho padronizado, 5 por-quês, brainstorming e observação direta.
Durante este estudo foi feita a observação direta de diversos setups e houve uma intera-ção com os operadores intervenientes no setup, para encontrar ações de melhoria e eliminar desperdícios, ou seja, ações que não acrescentam valor ao produto. Estas ações geraram ga-nhos de nove dias de máquina disponível ao final de um ano.
Através deste estudo foi possível alcançar o objetivo deste trabalho, reduzir os tempos de setup, criando rotinas de trabalho focadas em tornar algumas das etapas do setup mais rá-pidas, de modo a manter a qualidade do produto. O estudo tem algumas limitações, pelo impedimento de circulação livre pela fábrica devido ao vírus SARS-CoV-2.
Este trabalho apresenta as vantagens da aplicação de ferramentas de melhoria contínua para diminuir os tempos de setup de uma máquina ou uma linha de produção, aumentando a capacidade produtiva da mesma.
A redução dos tempos de setup permite à empresa optar por utilizar o tempo ganho para produzir uma maior quantidade de produto ou para aproveitar o facto de os setups ocuparem uma menor percentagem de tempo de produção para trocarem mais vezes de produto e, as-sim, acompanharem melhor as flutuações e as necessidades do mercado.
Over time, the pharmaceutical industry in Portugal has increased its sales per year. With this growth, companies feel the need to increase their productivity. This study was developed in a packaging line of a pharmaceutical company, with the main goal of reducing setup times. The reduction of setup times allows the reduction of non-productive times and thus increases the productivity of a factory. The methodology of the study begins with understanding the initial state of the setups on the packaging line, through data collection and analysis of setup times. Next, the improve-ments implemented in the packaging line and the results that come from these improvements are presented. Finally, improvements are described that can still be implemented in order to achieve better results. In order to development of this work was applied an A3 report and several tools related with Lean philosophy to support the development of the work, such as: SMED, PDCA cycle, 5S, Gantt chart, time collection, visual management, standardized work, 5 whys, brainstorm-ing, and direct observation. During this study, several setups were directly observed and there was interaction with those involved in the process, so that it was possible to find possible improvement actions and eliminate waste, that is, actions that do not add any value to the product. These actions generated gains of nine days of available machine at the end of a year. Through this study it was possible to achieve the objective of this work, to reduce setup times by creating work routines focused on making some of the process steps faster and more intuitive, in order to maintain the quality of the product. The study has some limitations, due the impediment of free movement around the plant due to the SARS-CoV-2 virus. This work demonstrates the advantages of applying continuous improvement tools to decrease the setup times of a machine or a production line, increasing its productive capacity. Reducing setup times allows the company to choose to use the time gained to produce a larger quantity of product, or to take advantage of the fact that setups take up a smaller percentage of production time to change products more often and thus better follow market fluctuations and needs.
Over time, the pharmaceutical industry in Portugal has increased its sales per year. With this growth, companies feel the need to increase their productivity. This study was developed in a packaging line of a pharmaceutical company, with the main goal of reducing setup times. The reduction of setup times allows the reduction of non-productive times and thus increases the productivity of a factory. The methodology of the study begins with understanding the initial state of the setups on the packaging line, through data collection and analysis of setup times. Next, the improve-ments implemented in the packaging line and the results that come from these improvements are presented. Finally, improvements are described that can still be implemented in order to achieve better results. In order to development of this work was applied an A3 report and several tools related with Lean philosophy to support the development of the work, such as: SMED, PDCA cycle, 5S, Gantt chart, time collection, visual management, standardized work, 5 whys, brainstorm-ing, and direct observation. During this study, several setups were directly observed and there was interaction with those involved in the process, so that it was possible to find possible improvement actions and eliminate waste, that is, actions that do not add any value to the product. These actions generated gains of nine days of available machine at the end of a year. Through this study it was possible to achieve the objective of this work, to reduce setup times by creating work routines focused on making some of the process steps faster and more intuitive, in order to maintain the quality of the product. The study has some limitations, due the impediment of free movement around the plant due to the SARS-CoV-2 virus. This work demonstrates the advantages of applying continuous improvement tools to decrease the setup times of a machine or a production line, increasing its productive capacity. Reducing setup times allows the company to choose to use the time gained to produce a larger quantity of product, or to take advantage of the fact that setups take up a smaller percentage of production time to change products more often and thus better follow market fluctuations and needs.
Descrição
Palavras-chave
Filosofia Lean Melhoria contínua Redução de tempos de Setup SMED Indústria Farmacêutica