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WAREHOUSE EXCELLENCE- EXCELÊNCIA EM ARMAZÉM. APLICAÇÃO DE METODOLOGIAS LEAN EM CONTEXTO DE ARMAZENAMENTO DE MATERIAIS INDUSTRIAIS
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O presente estudo teve como objetivos a melhoria da organização e da segurança no
armazém de materiais da ibéria da empresa Air Liquide, através da aplicação de metodologia
Lean nomeadamente na metodologia 5S.
Estudou-se a dinâmica do armazém, analisou-se o stock, o número de movimentos de
materiais, as vendas e as datas dos últimos consumos. Com base nestes dados foi planeada,
proposta e implementada uma nova organização do armazém. Esta permitiu libertar uma
área de 21 m2 e possibilitou o equivalente a uma poupança de 18 mil euros anuais, uma vez
que se evitaram custos adicionais, com o aluguer de um novo espaço. Diminuiu-se
aproximadamente 30% do tempo utilizado para localizar materiais e otimizar distâncias
percorrida no armazém. Foram usadas métricas financeiras, de utilização e de tempo.
Efetuou-se ainda uma análise de modos e efeitos de falha de modo a detetar falhas, por
forma a implementar medidas corretivas aumentando a segurança no armazém. Os modos de
falhas mais importantes foram paletes mal colocados no transporte, armazenamento fora dos
locais apropriados e materiais da mesma categoria armazenados em diversas áreas. Para
diminuir os impactos deverá ser realizada uma formação aos trabalhadores e a colocação de
placas identificativas. Estas medidas têm custos financeiros residuais, espera-se assim uma
diminuição de 50%, 80% e 90% destes modos de falha.
Verificou-se que o armazém cumpria na generalidade os requisitos de segurança, no
entanto, houve a necessidade de melhorar alguma sinalética e de arranjar ou substituir
estantes. Construí-se um catálogo de todas as etiquetas banana e válvulas existentes.
Durante a realização do estudo foi notada resistência à mudança por parte dos
trabalhadores, dificultando a implementação plena do projeto. Emerge da análise dos
resultados deste projeto, a recomendação da continuação da implementação da metodologia,
de modo que se continue a observar melhorias na organização do mesmo.
The present study aimed to improve the organization and safety of Air Liquide's mate- rials warehouse in Iberia, through the application of Lean methodology, namely the 5S meth- odology. The dynamics of the warehouse were studied, the stock, the number of material move- ments, sales and the dates of the last consumptions were analyzed. Based on these data, a new warehouse organization was planned, proposed and implemented. This allowed an area of 21 m2 to be freed and made possible the equivalent to a saving of 18 thousand euros a year, since additional costs were avoided, with the rental of a new space. Approximately 30% of the time used to locate materials and optimize distances trav- eled in the warehouse was reduced. Financial, utilization and time metrics were used. An analysis of failure modes and effects was also carried out in order to detect failures and to implement corrective measures, increasing safety in the warehouse. The most important failure modes were misplaced pallets in transport, off-site storage and materials of the same category stored in various areas. To reduce the impacts, training should be given to workers and the placement of identification plates. These measures have residual financial costs, so a 50%, 80% and 90% decrease in these failure modes is expected. It was found that the warehouse generally complied with safety requirements, however, there was a need to improve some signs and to arrange or replace shelves. A catalog of all existing banana labels and valves was built. During the study, resistance to change was noted on the part of workers, making it dif- ficult to fully implement the project. It emerges from the analysis of the results of this project, the recommendation to continue the implementation of the methodology, so that it continues to observe improvements in the organization of the same.
The present study aimed to improve the organization and safety of Air Liquide's mate- rials warehouse in Iberia, through the application of Lean methodology, namely the 5S meth- odology. The dynamics of the warehouse were studied, the stock, the number of material move- ments, sales and the dates of the last consumptions were analyzed. Based on these data, a new warehouse organization was planned, proposed and implemented. This allowed an area of 21 m2 to be freed and made possible the equivalent to a saving of 18 thousand euros a year, since additional costs were avoided, with the rental of a new space. Approximately 30% of the time used to locate materials and optimize distances trav- eled in the warehouse was reduced. Financial, utilization and time metrics were used. An analysis of failure modes and effects was also carried out in order to detect failures and to implement corrective measures, increasing safety in the warehouse. The most important failure modes were misplaced pallets in transport, off-site storage and materials of the same category stored in various areas. To reduce the impacts, training should be given to workers and the placement of identification plates. These measures have residual financial costs, so a 50%, 80% and 90% decrease in these failure modes is expected. It was found that the warehouse generally complied with safety requirements, however, there was a need to improve some signs and to arrange or replace shelves. A catalog of all existing banana labels and valves was built. During the study, resistance to change was noted on the part of workers, making it dif- ficult to fully implement the project. It emerges from the analysis of the results of this project, the recommendation to continue the implementation of the methodology, so that it continues to observe improvements in the organization of the same.
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Palavras-chave
Organização Segurança Metodologia Lean Gases industriais Armazém