Submitted by JOSIANE SANTOS DE OLIVEIRA (josianeso) on 2017-09-29T16:50:31Z No. of bitstreams: 1 Carline Fabiane Stalter_.pdf: 2749271 bytes, checksum: 1830f5c4b58dad8461d121b0d87ca2ca (MD5) / Made available in DSpace on 2017-09-29T16:50:31Z (GMT). No. of bitstreams: 1 Carline Fabiane Stalter_.pdf: 2749271 bytes, checksum: 1830f5c4b58dad8461d121b0d87ca2ca (MD5) Previous issue date: 2017-08-21 / CAPES - Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / CNPQ – Conselho Nacional de Desenvolvimento Científico e Tecnológico / PROSUP - Programa de Suporte à Pós-Gradução de Instituições de Ensino Particulares / A geração de resíduos em um processo deve ser evitada, tanto por questões econômicas como por questões ambientais, isso porque os resíduos gerados são compostos por matérias-primas que não se tornaram produto. Neste sentido, o presente trabalho busca avaliar oportunidades de melhoria através da ferramenta ambiental Produção mais Limpa (P+L) a fim de reduzir a quantidade de resíduos gerados no processo de embalagem da empresa Gama localizada no estado do Rio Grande do Sul. Este processo utiliza como matéria-prima o filme de polipropileno biorientado (BOPP), um polímero termoplástico resultante da orientação biaxial do filme de polipropileno (PP). Esses filmes são produzidos e vendidos pela empresa Alfa na forma de bobinas para a empresa Beta que realiza a impressão e então os comercializam. O processo de embalagem é realizado nas embaladoras horizontais do tipo Flow Pack que provem a selagem a quente do filme. Na empresa existem seis máquinas deste tipo, juntas geraram no ano de 2016, em média, 900kg de resíduo de embalagem de BOPP. Neste estudo foram selecionadas duas máquinas para serem estudadas e estas foram identificadas de acordo com o ano de fabricação: Flow Pack 84 e Flow Pack 07. A partir da avaliação in loco do processo em ambas as máquinas, foram identificadas as principais causas da geração de resíduo: rompimento do filme, falta de material, material trancado, material desalinhado e selagem inadequada. Com base em uma análise estatística por tabela de contingência e o diagrama de Pareto foram identificadas as principais falhas, ou seja, as que deveriam ser sanadas com prioridade: falta de material para a Flow Pack 07 e material trancado para a Flow Pack 84. Foi verificado ainda que a Flow Pack 84 gerava quase três vezes mais resíduos de embalagens quando comparada a Flow Pack 07. Assim, foram definidas ações de P+L visando a redução/eliminação de resíduo na fonte geradora. Com a instalação de uma esteira pulmão e de dois sensores de parada na Flow Pack 84 será possível eliminar a geração de resíduos por materiais trancados, pois quando algum material venha trancar o sensor identificará e interromperá o processo. Quanto a Flow Pack 07, a falta de material não depende da máquina em si, mas sim da qualidade do material que é alimentado nela, ou seja, é um problema que deve ser resolvido antes do processo de embalagem. A análise de viabilidade econômica realizada através do PayBack simples mostrou que o investimento realizado com as mudanças será recuperado em pouco mais de 1 ano. Com a implantação da melhoria no processo será reduzida a geração de resíduos de embalagem em 63,4% na Flow Pack 84, e consequentemente, serão reduzidos os impactos ambientais negativos causados não apenas pelo processo de embalagem, mas também por toda a cadeia produtiva do BOPP. / The generation of waste in a process should be avoided, both for economic and environmental reasons , because waste is composed of raw materials that have not become a product. In this sense, the present work seeks to evaluate improvement opportunities through the Cleaner Production (CP) environmental tool in order to reduce the amount of waste generated in the packaging process of a company Gama located in the state of Rio Grande do Sul. This process uses as a raw material bioriented polypropylene film (BOPP), a thermoplastic polymer resulting from the biaxial orientation of the polypropylene film (PP). These films are produced and sold by the company Alfa in the form of reels for the company Beta that do the printing and then sell them. The packaging process is carried out on the horizontal packers of the Flow Pack machines that provide the heat sealing of the film. In the company there are six machines of this type that together generated in the year 2016, on average, 900kg of packaging waste of BOPP. In this study two machines were defined to be studied and identified according to the year of manufacture: Flow Pack 84 and Flow Pack 07. From the on-site evaluation of the process in both machines, the main causes of waste generation were identified: Disruption of the film, lack of material, locked material, misaligned material and inadequate sealing. The statistical analysis by contingency table and the Pareto diagram showed the main failures, those that should be addressed with priority: lack of material for Flow Pack 07 and material locked for Flow Pack 84. It was also verified that Flow Pack 84 generated almost three times more packaging waste when compared to Flow Pack 07. Thus, CP actions were defined in order to reduce or eliminate waste in the generating source. With the installation of a lung treadmill and two stop sensors in the Flow Pack 84 it would be possible to eliminate the generation of waste by stucked materials, because when some material stuck into the machine the sensor would identify and interrupt the process. As for Flow Pack 07 the lack of material does not depend on the machine itself, but on the quality of the material that is fed into it, so, it is a problem that must be solved before the packaging process. The economic viability analysis performed through simple PayBack showed that the investment made with the changes would be recovered in just over a year. With the improvement of the process, the generation of packaging waste would be reduced by 63,4% in Flow Pack 84 and consequently the negative environmental impacts caused not only by the packaging process but also by the entire BOPP production chain would be reduced.

In an increasingly competitive market, it is important for companies with distribution centers to have efficient processes limiting non-value adding time as much as possible while still being able to deliver what the customer expects. The purpose of the thesis was to investigate the operating processes at the distribution center at Volvo – Eskilstuna. It services the Scandinavian market with multiple departures per day, supplying directly to end customers and retailers. The goal was to increase the efficiency of the distribution center and increase consolidation of multiple parts ordered by the same customer. Currently, multiple packages get delivered to the same customer who has ordered parts the same day. While investigating this inefficiency, we monitored orders through it registering in the system, assignment to picking lists to be picked by operators, packaging and sorting. There were constraints associated with the layout, IT system and traffic safety laws without compromising on delivery efficiency, quality, implementation costs, and organizational regulations. Observations were carried out on the job floor, interviews were conducted with the management or better: with managers / management team, and an independent analysis was conducted of the historical data collected from the warehouse management system. The main results suggest rearranging the inventory according to consumption frequency classification (Paretto principle). Additional results suggest implementing slotting and postpone packaging to consolidate higher order percentage. Multiple strategies have been put forth which need trials to test the implications. / I en ökad konkurrenskraftig marknad är det viktigt för företag med distributionscenter att få effektivare processer och minimera icke värdeskapande aktiviteter. Detta är nödvändigt för att möta kundernas förväntningar och leverera det som kunderna begär. Syftet med uppsatsen var att undersöka hur processerna fungerade på Volvos distributioncentret i Eskilstuna. Volvo levererar reservdelar till hela den skandinaviska marknaden och har flertal leveranser som lämnar distributioncentret dagligen. Målet var att öka effektiviteten i distributionscentret och möjliggöra konsolideringen när en kund beställt flera varor så att de kommer i samma paket. För närvarande levereras de olika varor i separata paket istället för att komma i en och samma. För att undersöka detta fenomen så samlades data in genom det som registrerades i systemet. Det fanns begränsningar i samband med lagstiftningen, IT-systemet och trafiksäkerhetslagar samt att lösningarna inte skulle kompromissa med leveranseffektivitet, kvalitet, implementeringskostnader och organisatoriska föreskrifter. Observationer genomfördes på arbetsplatsen, intervjuer genomfördes med ledningsgruppen eller relevanta chefer och en oberoende analys genomfördes av de historiska data som samlats in från lagerhanteringssystemet. De viktigaste resultaten föreslår att reservdelar bör förvaras efter Paretto principen som har med konsumtion frekvensen att göra. Ytterligare resultat föreslår att man ändrar på hur varor paketeras samt skjuter upp förpackningar för att konsolidera högre orderprocent.

The project focuses on the packaging process of the smart card manufacturing industry. The idea of the project concerns how to increase production packaging efficiency by introducing a control system. After taking an in-depth look at the current production environment, the following system goals were defined: packaging time reduction, cost reduction, decrease in human errors, and reducing the number of customer complaints. To achieve these goals, the thesis project was divided into the following tasks: discovering a feasible solution, actual system development, testing, and evaluation. The proposed system is based on hardware (i.e. barcode scanner, and barcode printer) integrated with customized control software. The barcode scanner acts as a bridge between the system and the production process by scanning a barcode printed on each product. The system prints the required information label for the product’s package according to the scanned product. This label is pasted on the product’s box and is used as a tracking tool during further production steps. The system is very flexible and suits any packaging model. Other functional properties maintained in the system include data security, product traceability, and real time production monitoring. Testing of the system was done in an actual production environment at an Oberthur Technologies manufacturing site. Two production lines were selected to test the system’s functionality, specifically the SIM card production packaging line and the Scratch card/ Bank Card production packaging line. The results obtained during the evaluation phase of the proposed system show that the proposed solution decreased the packaging processing time by (27.3%) over the previous values. Moreover, the resulting human error rate is close to (zero%). / Projektet fokuserar på förpackningen processen smartkortet tillverkningsindustrin. Tanken med projektet handlar om hur att öka effektiviteten produktionen förpackningar genom att införa ett styrsystem. Efter att ha tagit en fördjupad titt på den nuvarande produktionsmiljö, var följande systemkrav mål definieras: nedsättning förpackning tid, minskade kostnader, minskad mänskliga fel och minska antalet kundklagomål. För att uppnå dessa mål var examensarbetet indelad i följande uppgifter: att upptäcka en genomförbar lösning, faktisk systemutveckling, testning och utvärdering. Det föreslagna systemet bygger på hårdvara (dvs streckkodsläsare och streckkod skrivare) integreras med skräddarsydd styrprogram. Den streckkodsläsare fungerar som en bro mellan systemet och produktionsprocessen genom att läsa en streckkod tryckt på varje produkt. Systemet skriver den erforderliga informationen etiketten för produktens förpackning enligt den scannade produkten. Denna etikett klistras in på produktens ask och används som ett verktyg för spårning under ytterligare produktionssteg. Systemet är mycket flexibelt och passar varje förpackning modell. Andra funktionella egenskaper bibehålls i systemet inkluderar datasäkerhet, spårbarhet och i realtid övervakning av produktionen. Testning av systemet gjordes i en verklig produktionsmiljö i ett Oberthur Technologies tillverkningsanläggning. Två produktionslinjer valdes för att testa systemets funktionalitet, särskilt i SIM-kortet produktionen förpackning linje och skrapkort / Bank kortproduktion förpackningslinje. De resultat som erhållits under utvärderingsfasen av det föreslagna systemet visar att den föreslagna lösningen minskade tiden förpackningen behandling av (27,3 %) jämfört med föregående värden. Dessutom är den resulterande mänskliga fel som ligger nära (noll %).

The following thesis project has been done in direct collaboration with Autokaross i Floby AB Rescue Vehicle Department, in Sweden.  The report contains the design development of a protective cover against weather conditions for the extendable ladder in a fire vehicle.   The aim of the report has been to develop a functional and low cost solution cover for the FEL on a fire truck, which is allocated on the roof, with the express intention of providing adequate access and protection against weather conditions in Nordic countries, so as to prevent premature deterioration of the FEL unit. The company has set the technical and conceptual boundaries, with the help of the two previous concepts currently used, the BMC and the ACP.   The initial requirements laid out by the company were expressed through a number of specific demands which can be categorized in two main points:   Cost: Designing a solution keeping in mind cost limits, assembly cost and time, and space optimization. This was done by taking into account the two existing solutions, particularly the BMC, which represents the lowest, cost wise and function wise. Therefore it was used as the basis on which to apply improvements, rather than trying to lower the high cost on the overqualified function of the ACP.   Function: Providing the adequate protection and access to the FEL. In this case, the problem was solved by establishing the correct degree of protection relevant to the Nordic weather conditions and FEL needs, and regarding the access, this was assured by fully automating the opening/closing process with the existing extraction operating system of the FEL.     The result of this report is a concept solution which meets the company’s demands, obtained by creative detailing, together with an analysis regarding possible considerations that could improve the creative detailing result in this report in the form of future work.     The report documents the process that has taken place in exploration, concept generation, concept evaluation, concept selection, and detailed CAD development. Each section shows the requirements and adjustments taken to fulfil the company’s needs.