Orientador: Flávio Vasconcelos da Silva / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Química / Made available in DSpace on 2018-08-23T03:09:02Z (GMT). No. of bitstreams: 1 Frias_AlessandroRodrigues_M.pdf: 5596398 bytes, checksum: df7498d6968158f9178e007fdd72c6ff (MD5) Previous issue date: 2013 / Resumo: A Gestão de Malhas de Controle ou CLM (Control Loop Management) tem-se mostrado uma ferramenta importante para monitorar o funcionamento das malhas de controle nas indústrias, permitindo aumentar a produtividade e a qualidade por meio da redução no consumo de insumos e estabilidade da planta. Com isso, têm-se as justificativas necessárias para se pesquisar e aprimorar as técnicas existentes para gestão de malhas de controle nas indústrias. Este trabalho apresenta um estudo de caso sobre Gestão de Malhas de Controle em ambiente industrial por meio de um procedimento prático utilizando a metodologia DMAIC (Definir, Medir, Analisar, Implementar e Controlar) e também os principais índices de desempenho utilizados no software Sindus OPP como: Variabilidade, Erro Médio, Integral do Erro Absoluto (IAE), Índice de Capabilidade do Processo (CPK), Cruzamento de Setpoint (SP), Percurso da Válvula, Reversão e Saturação da Válvula na gestão on-line de malhas de controle. A revisão bibliográfica abrange os principais conceitos de gestão de malhas de controle, fundamentação teórica sobre a metodologia proposta para gestão de malhas, indicadores de desempenho e também sobre o processo de fabricação de papel, pois o estudo de caso apresentado neste trabalho foi realizado em malhas de controle do sistema de preparação de massa para fabricação de papel. Dentre os resultados obtidos destaca-se a redução de variabilidade das malhas de controle de nível do tanque de água fresca (96,9% menor), do tanque de massa refinada (98,6% menor) e do tanque de mistura (98,3% menor). A redução dos KPIs Técnicos das malhas de controle mostra que as ferramentas de gestão on-line de malhas de controle utilizadas no software Sindus OPP são práticas e eficazes, pois, permitiram fazer a gestão das malhas com foco em redução de variabilidade e melhoria contínua do processo de fabricação de papel / Abstract: The Control Loop Management (CLM) has been an important tool to monitoring the operation of the control loops in industry, allowing to increase productivity and quality through reducing the consumption of raw materials and plant stability. With this, there are the necessary justifications to research and improve the existing techniques for managing control loops in industry. This paper presents a case study on Control Loop Management in industrial environment by a practical procedure using the DMAIC methodology (Define, Measure, Analyze, Improve and Control) and the key performance indicators used in software Sindus OPP: Variability, Average Error, Integral of Absolute Error (IAE), Process Capability Index (CPK), Setpoint (SP) Crossing, Valve Travel, Valve Reversals and Valve Out Limit in online control loop management. The literature review includes the major concepts of Control Loop Management, the theoretical foundation of the proposed methodology for managing loops, performance indicators and also about the papermaking process, because the case study presented in this paper was performed on control loops of the stock preparation system for papermaking. Among the results highlight the variability reduction of control loops of the level of fresh water tank (96.9% less), of the refined pulp tank (98.6% less) and mixing tank (98.3% less). The reduction of Technical KPIs of control loops shows that the online management tools of control loops used in software Sindus OPP is practical and effective, because it allowed to manage the loops with focus on reducing variability and continuous improvement of papermaking process / Mestrado / Sistemas de Processos Quimicos e Informatica / Mestre em Engenharia Química

Thesis (MScIngwet)--University of Stellenbosch, 2004. / ENGLISH ABSTRACT: This thesis is a case study in optimal inventory control, applied to Clickabox factory, a South African cardboard box producer from whom cardboard boxes may be ordered at short notice via the internet. The problem of developing a decision–support system for optimal stockholding at the factory, in order to minimize cardboard off–cut wastage subject to required service levels, is addressed in this thesis. Previously a simple replenishment policy, based largely on experience, was implemented at the factory. The inventory model developed for and applied to Clickabox in this thesis takes account of a raw materials substitution cascade, as well as the stochasticity of demand, and other factors such as cost, service level and spatial requirements for the storage of stock. This combination of stochastic demand and product substitution has not, to the author’s knowledge, previously been dealt with in the literature. There are two primary deliverables of this study. The first is a suggestion as to the suitable stock composition (cardboard types from which boxes may be manufactured) to be kept in inventory at the factory. The second deliverable is a computerised decision–support system, based on the inventory model developed, to aid in future inventory replenishment decisions at Clickabox. Some of the results of this thesis have, at the time of writing, already been implemented with success at the factory. These include the suggestions given to the management of Clickabox as to the suitable stock types to be held in inventory, which have been implemented in stages since March 2003. The suggested stock composition has proven to be superior to the previous stock types held, in terms of a reduction in off–cut wastage and increased availability of suitable boards. / AFRIKAANSE OPSOMMING: Hierdie tesis is ’n gevallestudie in optimale voorraadbeheer, toegepas op Clickabox fabriek, ’n Suid–Afrikaanse kartondoosprodusent by wie kartondose op kort kennisgewing via die internet bestel kan word. In hierdie tesis word ’n besluitnemingsteunstelsel ontwikkel vir optimale bestuur van voorraad by die fabriek, wat karton afknipselvermorsing onderhewig aan vereiste diensvlakke minimeer. Vantevore is ’n eenvoudige voorraad aanvullingstrategie, wat hoofsaaklik op ondervinding gebaseer was, by die fabriek toegepas. ’n Wetenskaplike gefundeerde voorraadmodel word vir Clickabox ontwikkel en toegepas, waarin ’n rou–voorraad kaskade– substitusie proses in aanmerking geneem word, asook die stogastiese vraag na kartondose en faktore soos prys, diensvlakke en benodigde stoorruimte. Hierdie kombinasie van stogastiese vraag en rou–voorraad kaskade–substitusie is, tot die skrywer se kennis, nog nie in die literatuur behandel nie. Die studie het twee hoof–uitkomste ten doel. Die eerste is ’n aanbeveling ten opsigte van ’n geskikte rou–voorraad samestelling (kartontipes waaruit kartondose geproduseer kan word) wat by die fabriek in voorraad gehou moet word. Die tweede is ’n rekenaarmatige besluitnemingsteunstelsel, wat op die ontwikkelde voorraadbeheermodel gegrond is, en wat vir toekomstige besluite in verband met voorraadaanvulling by Clickabox bedoel is. Van die resultate wat in hierdie tesis vervat is, is reeds ten tyde van die opskryf daarvan doeltreffend by die fabriek ge¨ımplementeer. Ondermeer is die aanbeveling in verband met die geskikte voorraadsamestelling, geleidelik vanaf Maart 2003 by die fabriek ingefaseer. Dit het duidelik geword dat hierdie samestelling beter as die vorige voorraadprofiel funksioneer, in terme van ’n verlaging in afknipselvermorsing en ’n verhoging in die beskikbaarheid van geskikte kartonne.