Orientador: Antonio Batocchio / Dissertação (mestrado profissional) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-11T07:20:48Z (GMT). No. of bitstreams: 1 Fagundes_RenatoAlexandre_M.pdf: 1173048 bytes, checksum: f9c42d8865a1d2718c308d673b82bd20 (MD5) Previous issue date: 2007 / Resumo: Este trabalho tem como objetivo a implementação de um processo cadenciador (ou puxador) na linha de produção de uma indústria fabricante de placas de circuito impresso rígidas, focando principalmente na implantação de um sistema cadenciador para que o fluxo de produção flua de uma maneira cadenciada e limpa para atender uma determinada família de produtos de placas de circuito impresso rígido (não metalizadas ¿simples face¿ e metalizadas ¿dupla face¿). A montagem da célula de produção para o estudo foi desenvolvida a partir da análise da técnica de mapeamento de fluxo estendido para se obter a melhor produtividade do sistema e atender as demandas do cliente final. A existência de algumas formas de variabilidades nos tempos takt, balanceamento de operadores, tempo para troca de modelos e dimensionamento do ciclo de máquinas foram estudadas e apresentadas buscando sempre uma otimização do fluxo contínuo dentro do processo cadenciador. Através das técnicas de mapeamento de fluxo de valor foi montado um mapa de estado atual e futuro o qual nos permite visualizar de uma maneira mais clara as correções propostas. Palavras chaves: Manufatura enxuta, Mapeamento de Fluxo de Valor, Tempo Takt, OBC / Abstract: This work has as objective the implementation of a pacemaker process in the line of production of an industry manufacturer of rigid printed circuit board, where the major is on the implantation of a pacemaker process allowing a production flow clean and smoth for one definitive product family of the printed circuit board (not metallized "single face" and metallized "double face"). The assembly of the cell of production for the study was developed from the analysis of the technique of Mapping Stream Value to get the best productivity of the system and to take care of the demands of the final customer. The existence of some forms of variabilities like : takt time, balancing of operators, time for exchange of models and sizing of the cycle of machines had been studied and presented searching always an optimization of the continuous flow inside of the pacemaker process. Through the techniques of Mapping Stream Value from the current state to future state was mounted which in allows them to visualize in a clear way of the corrections proposals. Key words- Lean Manufacturing, Value Stream Mapping, Takt Time, OBC / Mestrado / Planejamento e Gestão Estrategica da Manufatura / Mestre em Engenharia Mecânica

The objective of the cellular manufacturing is to simplify the management of the<p>manufacturing industries. In regrouping the production of different parts into clusters,<p>the management of the manufacturing is reduced to manage different small<p>entities. One of the most important problems in the cellular manufacturing is the<p>design of these entities called cells. These cells represent a cluster of machines that<p>can be dedicated to the production of one or several parts. The ideal design of a<p>cellular manufacturing is to make these cells totally independent from one another,<p>i.e. that each part is dedicated to only one cell (i.e. if it can be achieved completely<p>inside this cell). The reality is a little more complex. Once the cells are created,<p>there exists still some traffic between them. This traffic corresponds to a transfer of<p>a part between two machines belonging to different cells. The final objective is to<p>reduce this traffic between the cells (called inter-cellular traffic).<p>Different methods exist to produce these cells and dedicated them to parts. To<p>create independent cells, the choice can be done between different ways to produce<p>each part. Two interdependent problems must be solved:<p>• the allocation of each operation on a machine: each part is defined by one or<p>several sequences of operations and each of them can be achieved by a set of<p>machines. A final sequence of machines must be chosen to produce each part.<p>• the grouping of each machine in cells producing traffic inside and outside the<p>cells.<p>In function of the solution to the first problem, different clusters will be created to<p>minimise the inter-cellular traffic.<p>In this thesis, an original method based on the grouping genetic algorithm (Gga)<p>is proposed to solve simultaneously these two interdependent problems. The efficiency<p>of the method is highlighted compared to the methods based on two integrated algorithms<p>or heuristics. Indeed, to form these cells of machines with the allocation<p>of operations on the machines, the used methods permitting to solve large scale<p>problems are generally composed by two nested algorithms. The main one calls the<p>secondary one to complete the first part of the solution. The application domain goes<p>beyond the manufacturing industry and can for example be applied to the design of<p>the electronic systems as explained in the future research.<p> / Doctorat en Sciences de l'ingénieur / info:eu-repo/semantics/nonPublished

This thesis deals with the analysis of data obtained by observing and measuring workplaces of assembly lines with a focus on the efficiency of their utilization, through selected elements of industrial engineering, which the reader can get acquainted with in the theoretical part of the thesis. In this thesis the line productivity during the shifts is analyzed, an ideal line balancing condition is defined and suggestion for changing the time of line consumption norm according to the measured line cycle time is made. According to the complex analyzes of the workplaces, suggestions are concluded and an economic appreciation of these proposals is also elaborated. The author of this thesis finds the main benefit of this work in increasing of the productivity of the analyzed line in the case of implementation of solution designs.

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Lean Manufacturing (LM) en la actualidad, es una de las metodologías de trabajo más aplicadas en las compañías que buscan eliminar los desperdicios de la operación, en base a la filosofía de mejora continua. Esto con el fin de que sus procesos internos se vuelvan más esbeltos y por ende más eficientes. En el presente estudio se podrá apreciar cómo un modelo de mejora basado en la combinación de algunas herramientas Lean tales como VSM, SMED y Manufactura celular, puede ser aplicado para optimizar las operaciones de una empresa de supermercados que produce panes a gran escala y de manera automatizada. Los panes son elaborados en una planta de producción de alimentos, para luego ser distribuidos a las distintas sedes del supermercado en donde se produce la venta final del producto. Algunos de los beneficios más relevantes que se identificaron después de la implementación de este modelo son el ahorro de costos de operación y distribución; así como el cumplimiento de la cuota de producción inicialmente planteada para la línea de panadería. / Lean Manufacturing (LM) is currently one of the most applied work methodologies in companies seeking to eliminate waste from the operation, based on the philosophy of continuous improvement. This in order that their internal processes become more slender and therefore more efficient. In the present study it will be appreciated how an improvement model based on the combination of some Lean tools such as VSM, SMED and Cellular Manufacturing, can be applied to optimize the operations of a supermarket company that produces bread on a large scale and in a automated. The breads are made in a food production plant, and then they are distributed to the different branches of the supermarket where the final sale of the product takes place. Some of the most relevant benefits that were identified after the implementation of this model are savings in operating and distribution costs; as well as the fulfillment of the production quota initially set for the bakery line. / Trabajo de Suficiencia Profesional

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由於少量多樣的生產趨勢，單元製造系統(Cellular Manufacturing Systems)已成為目前製造業的重點之一。在單元製造系統中，具有多種技能的員工是必備的條件，如何有效的配置人力策略即為本研究的重點。人力配置策略包含了指定式（由單一操作員負責某件工作）、共享式（由兩名或兩名以上操作員共同負責某件工作）及混合式人力配置策略（同時使用指定式和共享式兩種策略），其中，共享式和混合式的人力配置策略可稱為彈性人力配置策略。要使用彈性人力配置策略，需要有人力彈性(Labor Flexibility)。 　　所謂的人力彈性在單元製造系統可分為兩個方向：(1)單元間的人力彈性(Inter-Cell Labor Flexibility)，即不同單元間的轉換能力，(2)單元內的人力彈性(Intra-Cell Labor Flexibility)，即單元內不同工作間的轉換能力。本研究分為兩個主要部份，分別探討在單元間採用彈性人力配置策略和在單元內採用彈性人力配置策略對於工作量平衡程度、工作量共享程度和績效表現的影響。 　　根據研究結果，在單元內採用彈性的人力配置策略對於操作員間的工作量平衡和績效表現皆有直接且正向影響，但隨著操作員數目的減少，彈性的人力配置策略對於績效表現之影響減弱、甚至變為負向效果；在單元間採用彈性的人力配置策略之效果和在單元內採用彈性的人力配置策略相似，對操作員間的工作量平衡和績效表現亦有直接且正向影響，且隨著單元數增加，在單元間採用彈性的人力配置策略對績效表現的影響增強。本研究之結果可做為運用彈性的人力配置策略以及規劃交互訓練時的參考方向，並可用此架構來預測績效改變。 / The object of the research is to study agile labor assignments in cellular manufacturing systems by intra-cell and inter-cell operator’s mobility. There are three labor assignments strategies including dedicated (only one operator is responsible for a work), shared (two or more than two operators are responsible for a work), and combined assignment (using both of dedicated assignment and shared assignment). Different assignments lead to different workload balancing, workload sharing and performance. The research builds a simulate framework which includes operators’ moving rule, proposition of empirical study and index of workload balancing and workload sharing. According the result of research, applying intra-cell operator’s mobility can improve operator’s workload balancing and performance. Nevertheless, the relationship of intra-cell operator’s mobility and performance would decrease with decreasing of labor limited. The impact of inter-cell operator’s mobility is similar to intra-cell operator’s mobility, but it would increase with increase of complexity. The simulate framework which pass through the testing can use in an actual company case, provide a direction of how to use labor assignments, and forecast the impact of using agile labor assignment.