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Publicação
Melhoria da Gestão da Manutenção de uma Fábrica de Palhinhas de Papel
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| 2.22 MB | Adobe PDF |
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Resumo(s)
A manutenção desempenha um papel fundamental dentro de qualquer organização
que pretenda manter os seus ativos em boas condições de funcionamento e responder a
cada um dos problemas detetados, através da implementação de ações de reparação e
melhoria.
O presente estudo foi realizado na Tetra Pak Tubex Portugal, uma fábrica especializada
na produção de palhinhas de papel. A fábrica objeto de estudo, recentemente transacionou a
sua produção de palhinhas de plástico para palhinhas de papel, devido a uma diretriz
aprovada pelo Parlamento Europeu, que criou problemas relacionados com a fiabilidade dos
sistemas de produção, havendo uma necessidade de melhorar as atividades de gestão da
manutenção praticadas na fábrica.
Este estudo tem como objetivo identificar as principais causas das falha da linha de
produção, efetuar uma análise da fiabilidade do equipamento considerado como ponto
crítico e propor um conjunto de ações de melhoria relacionadas com as atividades de gestão
de manutenção na fábrica.
Com base nas observações realizadas durante o estudo, foram desenvolvidas um
conjunto de propostas de melhoria a serem implementadas na linha de produção. Foi
sugerido à organização reforçar o horário dos técnicos de manutenção para aumentar a sua
disponibilidade, implementar um sistema para monitorizar KPIs global a toda a produção,
criar uma matriz de risco para priorizar as atividades de manutenção e estabelecer um
conjunto de regras a seguir em caso de falha.
No caso de implementação integral, é previsto uma diminuição de 17% do número de
interrupções da linha de produção, aumento de 50% da disponibilidade dos técnicos de
manutenção e poupar em 16 horas por mês de um dos trabalhadores.
O desenvolvimento do estudo foi auxiliado por observação direta, análise de
documentos internos, análise dos principais KPIs de controlo do desempenho de produção,
diagrama de Pareto, teste de Laplace, brainstorming, entre outros.
Maintenance plays a fundamental role within any organization that wants to keep its assets in good working order and respond to each problem detected by implementing repair and improvement actions. This study was carried out at Tetra Pak Tubex Portugal, a factory that specializes in the production of paper straws. The factory under study has recently switched its production from plastic straws to paper straws, due to a directive approved by the European Parliament, which has created problems related to the reliability of production systems, resulting in a need to improve the maintenance management activities practiced at the factory. The aim of this study is to identify the main causes of production line failures, carry out a reliability analysis of the equipment considered to be the critical point and propose a set of improvement actions related to the factory's maintenance management activities. Based on the observations made during the study, a set of improvement proposals were developed to be implemented on the production line. It was suggested that the organization reinforce maintenance technician’s hours to increase their availability, implement a system to monitor global KPIs for all production, create a risk matrix to prioritize maintenance activities and establish a set of rules to follow in the event of a failure. In the case of full implementation, it is expected that there will be a 17% reduction in the number of interruptions to the production line, a 50% increase in the availability of maintenance technicians and a saving of 16 hours per month for one of the workers. The development of the study was aided by direct observation, analysis of internal documents, analysis of the main production performance control KPIs, Pareto diagram, Laplace test, brainstorming, among others.
Maintenance plays a fundamental role within any organization that wants to keep its assets in good working order and respond to each problem detected by implementing repair and improvement actions. This study was carried out at Tetra Pak Tubex Portugal, a factory that specializes in the production of paper straws. The factory under study has recently switched its production from plastic straws to paper straws, due to a directive approved by the European Parliament, which has created problems related to the reliability of production systems, resulting in a need to improve the maintenance management activities practiced at the factory. The aim of this study is to identify the main causes of production line failures, carry out a reliability analysis of the equipment considered to be the critical point and propose a set of improvement actions related to the factory's maintenance management activities. Based on the observations made during the study, a set of improvement proposals were developed to be implemented on the production line. It was suggested that the organization reinforce maintenance technician’s hours to increase their availability, implement a system to monitor global KPIs for all production, create a risk matrix to prioritize maintenance activities and establish a set of rules to follow in the event of a failure. In the case of full implementation, it is expected that there will be a 17% reduction in the number of interruptions to the production line, a 50% increase in the availability of maintenance technicians and a saving of 16 hours per month for one of the workers. The development of the study was aided by direct observation, analysis of internal documents, analysis of the main production performance control KPIs, Pareto diagram, Laplace test, brainstorming, among others.
Descrição
Palavras-chave
Gestão da Manutenção Fiabilidade Disponibilidade Operacional Rendimento Sistema Reparável e MTBF