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Implementação de um Modelo integrado TLS num sistema produtivo Lean
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Orientador(es)
Resumo(s)
A presente investigação é realizada na Corticeira Amorim, mais precisamente na
Unidade Industrial Equipar, situada em Coruche. Esta unidade divide-se em quatro fá-
bricas: Trituração, Unidade de Aglomerados, Unidade de Twin-top e Equipar Distribui-
ção (EQD). O estudo apresentado foca-se principalmente na Unidade de Aglomerados e
na EQD.
Com o objetivo de satisfazer os pedidos dos clientes a tempo e horas surge a ne-
cessidade de se aumentar o nível de serviço da EQD, isto é, satisfazer os pedidos dos
clientes dentro do tempo esperado. Após a recolha e análise do estado da arte, concluiu-
se que, atualmente, os modelos híbridos TLS são aqueles que, em termos práticos, apre-
sentam melhor desempenho, estes resultam da integração da Teoria das Restrições com
o Lean e Six Sigma. Como tal, inicialmente desenvolveu-se um modelo integrador que
agrupou as melhores caraterísticas de cada uma das três metodologias, tendo sido pos-
teriormente implementado no sistema em estudo, seguindo-se uma lógica de Case Study.
Durante a realização do estudo bibliográfico, analisaram-se os modelos integrado-
res existentes, em seguida concebeu-se um modelo TLS composto por 5 fases sendo elas
as seguintes: Análise e identificação do processo restritivo; Exploração da restrição uti-
lizando as ferramentas Lean e Six Sigma; Subordinação do sistema à restrição; Elevação
da restrição, caso seja possível; e, por fim, Avaliação da restrição. Nos casos em que a
restrição esteja resolvida, o ciclo termina e retoma-se um novo ciclo no primeiro passo.
Por fim, implementou-se o modelo, sendo que se realizaram dois ciclos de melhoria con-
tínua. O nível de Serviço Acumulado aumentou 3% relativamente ao ano anterior, esta-
belecendo-se agora nos 94%.
The present study is carried out at Corticeira Amorim, more precisely at the Equi- par Industrial Unit, located in Coruche. This unit is divided into four factories: Crushing, Twin-top Unit, Agglomerates Unit and Equipar Distribution (EQD); The present study focuses mainly on the last two. With the objective of satisfying customer orders on time, the need to increase the service level of EQD arises. Currently the best performing methodology is the TLS hy- brid model, which results from the integration of Theory of Constraints with Lean and Six Sigma. An integrative model of the three methodologies was developed and then implemented in the system under study, following a case study logic. After a bibliographic study, where the existing models were analyzed, a TLS model was conceived, composed of 5 phases that are based on: Analysis and identifica- tion of the restrictive process; Exploration of the restriction through Lean and Six Sigma tools; Subordination of the system to the restriction; Lifting of the restriction, if possible; and the evaluation of the restriction. In cases where the constraint is solved, the cycle closes and a new one starts in the first step. Finally, the model was implemented, and two cycles of continuous improvement were performed. The system's constraint was identified in each cycle and acted upon in order to get the most profitability and effi- ciency out of it. The implementation of the project has produced very positive results. The Accu- mulated Service level increased 3% compared to the previous year, and now stands at 94%. This increase was not higher due to a fire at the facilities that forced production to stop for about two weeks, resulting in delays in order deliveries.
The present study is carried out at Corticeira Amorim, more precisely at the Equi- par Industrial Unit, located in Coruche. This unit is divided into four factories: Crushing, Twin-top Unit, Agglomerates Unit and Equipar Distribution (EQD); The present study focuses mainly on the last two. With the objective of satisfying customer orders on time, the need to increase the service level of EQD arises. Currently the best performing methodology is the TLS hy- brid model, which results from the integration of Theory of Constraints with Lean and Six Sigma. An integrative model of the three methodologies was developed and then implemented in the system under study, following a case study logic. After a bibliographic study, where the existing models were analyzed, a TLS model was conceived, composed of 5 phases that are based on: Analysis and identifica- tion of the restrictive process; Exploration of the restriction through Lean and Six Sigma tools; Subordination of the system to the restriction; Lifting of the restriction, if possible; and the evaluation of the restriction. In cases where the constraint is solved, the cycle closes and a new one starts in the first step. Finally, the model was implemented, and two cycles of continuous improvement were performed. The system's constraint was identified in each cycle and acted upon in order to get the most profitability and effi- ciency out of it. The implementation of the project has produced very positive results. The Accu- mulated Service level increased 3% compared to the previous year, and now stands at 94%. This increase was not higher due to a fire at the facilities that forced production to stop for about two weeks, resulting in delays in order deliveries.
Descrição
Palavras-chave
TLS Teoria das Restrições Lean Six Sigma Melhoria contínua Fabricação de Rolhas de Cortiça