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PROPOSTA DE MELHORIA CONTÍNUA NA INDÚSTRIA FARMACÊUTICA
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Nos últimos anos, o mercado farmacêutico tornou-se cada vez mais competitivo e dinâmico,
exigindo a otimização dos processos de produção por parte das empresas. Um dos principais objetivos
dos responsáveis industriais é a redução de custos nas linhas de produção, de forma a responder às
fortes exigências da concorrência.
Esta dissertação foi realizada no contexto de uma linha de embalamento de uma empresa
farmacêutica, com o objetivo de reduzir os tempos de setup, de forma a aumentar a produtividade,
minimizando os tempos de paragem. Para além disso, foi identificada a necessidade urgente de me-
lhorar o processo de planeamento devido à escassez de materiais, que estava a ter um impacto nega-
tivo na produção. Para fazer face a este desafio, foi desenvolvido um plano de ação que incorporou
medidas preventivas.
A metodologia adotada incluiu a monitorização das atividades operacionais nas linhas de pro-
dução e a seleção de produtos com base numa análise ABC, bem como a avaliação dos dados OEE para
as linhas selecionadas. Na sequência da identificação dos problemas e de uma análise exaustiva da
literatura, foi proposta e implementada uma série de melhorias utilizando uma vasta variedade de
técnicas, incluindo o Diagrama de Ishikawa, 5S, Poka Yoke, normalização de atividades, observação
direta, recolha e análise de tempo e SMED.
O estudo utilizou uma metodologia que combinava a observação direta dos setups, associada
ao envolvimento dos operadores. Esta abordagem permitiu a identificação e eliminação de tarefas que
não contribuíam para o valor do produto. A implementação da ferramenta SMED, em conjunto com
outras melhorias, resultou numa redução de aproximadamente 40% nos tempos de setup nas linhas
de produção analisadas. Este estudo ilustra os benefícios da utilização de metodologias de melhoria
contínua para aumentar a capacidade de produção, minimizando os tempos de setup.
In recent years, the pharmaceutical market has become increasingly competitive and dynamic, requiring pharmaceutical companies to optimise their production processes in order to remain com- petitive. A key objective for industrial managers is to reduce costs on production lines in order to meet the demands of the competitive market. The aim of this research project was to investigate methods of reducing setup times on a phar- maceutical company's packaging line, with the goal of improving overall productivity while limiting periods of downtime. Furthermore, it was identified that improvements were required regarding the planning process, due to the shortage of materials, which was causing a negative impact on produc- tion. In order to address this challenge, an action plan was developed which incorporated preventative measures. The methodology involved monitoring operational activities on the production lines and se- lecting products based on an ABC analysis, as well as evaluating the OEE data for the selected lines. Following the identification of problems and a comprehensive review of the relevant literature, a series of improvements were proposed and implemented using a range of techniques, including the Ishikawa diagram, 5S, Poka Yoke, activity standardisation, direct observation, time collection and analysis, and SMED. The study employed a methodology that integrated direct observation of setups with operator involvement. This approach enabled the identification and elimination of tasks that did not contribute to the value of the product. The implementation of the SMED tool, in combination with other improve- ments, resulted in a reduction of approximately 40% in setup times on the production lines under analysis. This study demonstrates the advantages of employing continuous improvement methodolo- gies to enhance production capacity while reducing setup times.
In recent years, the pharmaceutical market has become increasingly competitive and dynamic, requiring pharmaceutical companies to optimise their production processes in order to remain com- petitive. A key objective for industrial managers is to reduce costs on production lines in order to meet the demands of the competitive market. The aim of this research project was to investigate methods of reducing setup times on a phar- maceutical company's packaging line, with the goal of improving overall productivity while limiting periods of downtime. Furthermore, it was identified that improvements were required regarding the planning process, due to the shortage of materials, which was causing a negative impact on produc- tion. In order to address this challenge, an action plan was developed which incorporated preventative measures. The methodology involved monitoring operational activities on the production lines and se- lecting products based on an ABC analysis, as well as evaluating the OEE data for the selected lines. Following the identification of problems and a comprehensive review of the relevant literature, a series of improvements were proposed and implemented using a range of techniques, including the Ishikawa diagram, 5S, Poka Yoke, activity standardisation, direct observation, time collection and analysis, and SMED. The study employed a methodology that integrated direct observation of setups with operator involvement. This approach enabled the identification and elimination of tasks that did not contribute to the value of the product. The implementation of the SMED tool, in combination with other improve- ments, resulted in a reduction of approximately 40% in setup times on the production lines under analysis. This study demonstrates the advantages of employing continuous improvement methodolo- gies to enhance production capacity while reducing setup times.
Descrição
Palavras-chave
Lean Manufacturing Indústria farmacêutica SMED planeamento observação direta