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Previsão e Padronização de Processos de Press-fit em Contatores através de Desenho de Experiências aplicado na Indústria Automóvel
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Resumo(s)
No enquadramento atual, caracterizado pela elevada competitividade entre organiza-
ções, é cada vez mais percetível a realização de esforços por parte destas no que toca à im-
plementação de metodologias e ferramentas que otimizem a sua proposta de valor. Num
contexto onde os requisitos dos clientes são cada vez mais exigentes e heterogéneos, torna-
se imperativo que as empresas tenham processos flexíveis, padronizados, e que assim lhes
permitam responder de forma célere ao mercado, ganhando vantagem competitiva.
Neste âmbito, a presente dissertação apresenta um procedimento de padronização e
previsão de processos
press-fit na produção de contatores, destinados a veículos elétricos.
Tem como objetivo a otimização e padronização de procedimentos de validação destes pro-
cessos, nomeadamente no que diz respeito à definição dos seus limites de controlo. Ao se-
rem definidos com base num só lote de componentes, a variabilidade entre lotes força uma
revalidação, que garante a estabilidade do processo para novas condições de matéria-prima.
Tendo como objeto de estudo a variabilidade geométrica dos componentes, com base
em vários lotes dos mesmos, é possível, através da aplicação de ferramentas como a Análise
de Variância, identificar as variáveis significativas a nível dimensional. Depois, com este co-
nhecimento, e recorrendo à ferramenta do Desenho de Experiências, é possível elaborar mo-
delos que conseguem prever em antemão a magnitude e correspondente impacto da varia-
bilidade dos componentes na estabilidade dos respetivos processos.
Ao modelar os processos com uso das tolerâncias dos
inputs, é possível prever os seus
outputs, garantindo a capacidade de ajustar atempadamente todos os limites de processo
com base nos dados de vários lotes. Assim, otimizando o procedimento de validação, tor-
nando-o independente de um só lote, é possível prever a tempo as alterações que devem ser
realizadas nos limites de processo. Desde modo, é promovida a estabilidade dos processos e
evita-se tanto situações de falta de qualidade, como desperdícios na forma de falsos alarmes.
Currently, the competitiveness among organizations has been increasing and the ef- forts made by these are increasingly noticeable regarding the implementation of tools and methodologies that optimize their value proposal. In a context where customer requirements are increasingly demanding and heteroge- neous, it is imperative for companies to have flexible, standardized processes that allow them to respond quickly to the market, thus gaining competitive advantage. In this context, in this dissertation a procedure for standardization and prediction of press-fit processes in the manufacture of contactors for electric vehicles is presented. The objective is to optimize and standardize the validation procedures of these processes, namely regarding the definition of their control limits. Since they are currently defined based on a single batch of components, the variability between batches forces a revalidation, which en- sures the stability of the process for the new raw material conditions. By focusing on the geometric variability of these components, based on several batch- es, through the application of tools such as the Analysis of Variance it is possible to identify the significant variables at the dimensional level. Then, with this knowledge, and using the tool of Design of Experiments, it is possible to develop models that can predict in advance the magnitude and corresponding impact of component variability on the stability of the respective processes. By modeling the processes using input tolerances, it is possible to predict their outputs, ensuring the ability to timely adjust all process limits based on multiple batch data. Thus, by optimizing the validation procedure to make it independent of a single batch, it is possible to predict in a timely manner the changes that need to be made to the process limits. In this way, process stability is promoted and both poor quality situations and waste in the form of false alarms are avoided.
Currently, the competitiveness among organizations has been increasing and the ef- forts made by these are increasingly noticeable regarding the implementation of tools and methodologies that optimize their value proposal. In a context where customer requirements are increasingly demanding and heteroge- neous, it is imperative for companies to have flexible, standardized processes that allow them to respond quickly to the market, thus gaining competitive advantage. In this context, in this dissertation a procedure for standardization and prediction of press-fit processes in the manufacture of contactors for electric vehicles is presented. The objective is to optimize and standardize the validation procedures of these processes, namely regarding the definition of their control limits. Since they are currently defined based on a single batch of components, the variability between batches forces a revalidation, which en- sures the stability of the process for the new raw material conditions. By focusing on the geometric variability of these components, based on several batch- es, through the application of tools such as the Analysis of Variance it is possible to identify the significant variables at the dimensional level. Then, with this knowledge, and using the tool of Design of Experiments, it is possible to develop models that can predict in advance the magnitude and corresponding impact of component variability on the stability of the respective processes. By modeling the processes using input tolerances, it is possible to predict their outputs, ensuring the ability to timely adjust all process limits based on multiple batch data. Thus, by optimizing the validation procedure to make it independent of a single batch, it is possible to predict in a timely manner the changes that need to be made to the process limits. In this way, process stability is promoted and both poor quality situations and waste in the form of false alarms are avoided.
Descrição
Palavras-chave
Padronização Previsão Press-fit Análise de Variância Desenho de Experiências