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MELHORIA DO OVERALL EQUIPMENT EFFECTIVENESS DA LINHA DE PRODUÇÃO ME21. REDUÇÃO DOS TEMPOS DE PEQUENAS PARAGENS E DE AJUSTES E AFINAÇÕES
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A presente dissertação reflete o trabalho desenvolvido durante o estágio curricular na empresa Upfield, no Departamento de Manutenção. Durante o estágio foram conhecidos os equipamentos e suas características, mais especificamente, o conjunto de máquinas que compõem a linha de produção de margarinas Me21, e foram estudados os diferentes tipos de perdas que reduzem a eficiência (OEE) da linha. Incidiu-se o trabalho na diminuição das perdas por Pequenas Paragens (P.P.) e Ajustes e Afinações (A.A.) e para as mesmas foram estudadas soluções para diminuir o seu impacto. No final, espera-se que o OEE médio da linha aumente acima de 70%.
Utilizaram-se Manuais de operação das máquinas da linha para averiguar as especificidades dos equipamentos e realizou-se um trabalho de campo na linha, acompanhando o trabalho dos operadores e técnicos de manutenção. Para além disso, estudaram-se conceitos e métodos de Melhoria Contínua, no-meadamente, a implementação dos 5S, SMED e TPM, e sua viabilização no contexto da fábrica. Con-sequentemente, foi criado um Projeto Centerlining, um projeto de Manutenção Autónoma (AM), um Procedimento para Mudanças de Formato da encaixotadeira e um Manual para Limpeza da linha. Para além disso, recorreu-se à utilização da aplicação Autodesk Fusion 360, e também de uma Impressora 3D para idealização e desenvolvimento de projetos para melhorar o funcionamento da linha e a quali-dade dos produtos desta; nomeadamente, criação de uma Pressionadora de caixas e um desenho 3D da linha de produção.
No final, conseguiu-se aumentar o OEE da linha, porém, derivado de alterações que foram feitas, não relacionadas com o Projeto de Melhoria Contínua, não foi possível ter uma imagem clara do impacto das melhorias nas P.P. e nos A.A.. Não obstante, conseguiu-se alcançar um OEE trimestral médio acima dos 70% e conseguiu-se diminuir o tempo de P.P. na encaixotadeira, que era um dos equipamentos que causavam mais P.P. na linha.
This thesis reflects the work developed during the curricular internship at Upfield, in the Mainte-nance Department. During the internship, the equipment and its characteristics were known, specifically, the set of machines that make up the margarine production line Me21 , and the different types of losses that reduce the efficiency (OEE) of the line were studied. The work focused on reducing losses by Minor Stoppages and Measurements and Adjustments, and for these were studied solutions to reduce their impact. In the end, the average OEE of the line is expected to increase above 70%. Operation manuals of the line machines were used to ascertain the specific characteristics of the equipments and a field work was carried out on the line to accompany the work of operators and main-tenance technicians. In addition, concepts and methods of Continuous Improvement were studied, na-mely, the implementation of 5S, SMED and TPM, and their feasibility in the context of the factory. Consequently, a Centerlining Project, an Autonomous Maintenance (AM) project, a Format Change Procedure and a Line Cleaning Manual were created. In addition, the Autodesk Fusion 360 application and a 3D Printer were used to design and develop projects to improve the operation of the line and the quality of its products; namely, creation of a Box press and a 3D drawing of the production line. In the end, it was possible to increase the line’s OEE, however, due to changes that were made to the line, not directly related to the Continuous Improvement Project, it wasn’t possible to have a clear image of the impact of the improvements in the Minor Stoppages and in the Measurements and Adjus-tments Time. Nevertheless, an average quarterly OEE above 70% was achieved and it was possible to reduce the time of Minor Stoppages in the boxing machine, which was one of the equipments that caused more Minor Stoppages.
This thesis reflects the work developed during the curricular internship at Upfield, in the Mainte-nance Department. During the internship, the equipment and its characteristics were known, specifically, the set of machines that make up the margarine production line Me21 , and the different types of losses that reduce the efficiency (OEE) of the line were studied. The work focused on reducing losses by Minor Stoppages and Measurements and Adjustments, and for these were studied solutions to reduce their impact. In the end, the average OEE of the line is expected to increase above 70%. Operation manuals of the line machines were used to ascertain the specific characteristics of the equipments and a field work was carried out on the line to accompany the work of operators and main-tenance technicians. In addition, concepts and methods of Continuous Improvement were studied, na-mely, the implementation of 5S, SMED and TPM, and their feasibility in the context of the factory. Consequently, a Centerlining Project, an Autonomous Maintenance (AM) project, a Format Change Procedure and a Line Cleaning Manual were created. In addition, the Autodesk Fusion 360 application and a 3D Printer were used to design and develop projects to improve the operation of the line and the quality of its products; namely, creation of a Box press and a 3D drawing of the production line. In the end, it was possible to increase the line’s OEE, however, due to changes that were made to the line, not directly related to the Continuous Improvement Project, it wasn’t possible to have a clear image of the impact of the improvements in the Minor Stoppages and in the Measurements and Adjus-tments Time. Nevertheless, an average quarterly OEE above 70% was achieved and it was possible to reduce the time of Minor Stoppages in the boxing machine, which was one of the equipments that caused more Minor Stoppages.
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Kaizen Linha de produção Me21 Manutenção Melhoria Contínua OEE