Orientador: Paulo Correa Lima / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-07T04:02:28Z (GMT). No. of bitstreams: 1 Calado_RobisomDamasceno_M.pdf: 2515663 bytes, checksum: 21c4fbba4a8cbe4ea49b31b3b7a19b49 (MD5) Previous issue date: 2006 / Resumo: A competitividade em mercados globalizados, bem como a inovação e difusão de novas técnicas e métodos, oriundas do Sistema Toyota de Produção e Controle de Qualidade Total, são aplicadas em fábricas de todo o mundo e tem alavancado constante melhoria nos postos de trabalho e considerável redução dos riscos de acidente, pois a segurança está no escopo da melhoria de produtividade e qualidade. Neste trabalho foca-se a eliminação do risco de acidente (problemática específica do objeto de estudo) através da aplicação dos conceitos e ferramentas da manufatura enxuta, como mapeamento do fluxo de valor e célula de manufatura, de forma integrada ao objeto de estudo e seus trabalhadores com uso da metodologia de pesquisa-ação, desta forma foi possível obter resultados qualitativos e aumento da produtividade no processo de injeção e tampografia de peças plásticas, este trabalho pode servir de motivação e fonte de pesquisa para se implementar melhorias nas inúmeras empresas do ramo plástico entre outros segmentos de manufatura de bens de consumo / Abstract: The competitiveness in global markets, as well as the innovation and diffusion of new techniques and methods, original from Toyota Production System and Total Quality Control, are applied in factories worldwide and have provided continuous improvement in workstations and a deep reduction of accident risks, because larger safety is the target of productivity improvement and quality. In this paper focused the elimination of the accident risk (specific problem of the object of study) through the application of the concepts and tools of Lean manufacturing, as Value Stream Mapping and Manufacture Cell, on way integrated the study object and their workers with use of research-action methodology, have been able to obtain qualitative results that can be useful as motivation and research sources for improvements implementation in many companies of plastic activity among other segments of consumption goods production / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica

The topic of this thesis is to optimize the production process of ferrite cores in the company Epcos, Ltd. The work is divided into theoretical, analytical and design part. The first part of the thesis contains theoretical knowledge within the field of lean manufacturing, process mapping and mapping value streams. Based on these findings is determined the theoretical basis for the processing of other parts of the thesis. The aim of the analytical part of the analysis is to map the current state of the manufacturing process, finding bottlenecks, evaluating the results of analysis of the current state, which will be used for the design part of the thesis, to develop proposals for optimizing production bottlenecks and evaluate their contribution.

The thesis is concerned with logistic processes optimization in automotive industry companies that assemble car components. In the theoretical part of the thesis, areas and a structure of industrial logistics are defined and frequently used terms are explained. Then, theoretical approaches and practical applications used in the practical part are described. In the practical part, two particular companies are presented. The aim of the thesis is to optimize a tool that is used in the first organization during the process of logistic preparation of manufacturing. Secondly, the aim of the thesis is to analyse the process of material picking and handling before the supply of assembly line that is performed in the second organization and to suggest a solution that would eliminate non-value added activities. In the end, benefits of the thesis for both the organizations and the author are summarized.

De nombreuses industries ont mené des recherches en vue de choisir la méthode appropriée afin d'améliorer les résultats, notamment Lean manufacturing et Six Sigma. Ce travail de thèse s’intéresse principalement à l’influence de l’implémentation de ces méthodes au sein des entreprises françaises, selon trois critères : financier, opérationnel et innovation. Les résultats de nos recherches montrent que les entreprises, appliquant Lean manufacturing et Six Sigma, sont plus efficacies pour l'amélioration des performances en matières financière et opérationnelle. Par ailleurs, les entreprises qui utilisent juste une partie des pratiques de Lean manufacturing et/ou de Six Sigma ont montré des améliorations limitées. En ce qui concerne le volet innovation, nous avons montré que l’implémentation de Lean manufacturing est suffisante pour avoir une amélioration des performances. En outre, nous avons constaté que les pratiques de Lean manufacturing et Six Sigma, telles que One Piece Flow, Kanban, 5S, etc. contribuent fortement à l’amélioration des performances. Les résultats statistiques montrent également que les facteurs clés, de la réussite de la mise en place de Lean et Six Sigma, peuvent être significativement différents selon la méthode. / Many industries conduct research in order to decide on the appropriate methodology for delivering optimal performance outcomes such as Lean Manufacturing or Six Sigma. Therefore, this research shows the influence of different categories based on the implementation method against three criteria: financial performance, operational performance and innovation performance. Research results indicate that companies implementing Lean Manufacturing and Six Sigma were more effective in improving company performance across financial and operational dynamics. Additionally, it shows companies who implemented Lean Manufacturing only saw improvements in innovation performance. Moreover, we found that Lean Manufacturing and Six Sigma practices such as One Piece Flow, Kanban, 5S, etc, supported increases in companies’ performance. The statistical results also show that the key factors for the success of Lean Manufacturing and Six Sigma implementation could differ depending on the method employed.

This Master's thesis deals with the optimization of the material flow between two areas of the production plant of the selected company. At the beginning of the thesis there is shown theoretical framework which is needed for subsequent analysis and determination of the proposals to improvement. In this part there is pointed out to the understanding of the process and the various concepts related to the process management. Furthermore, for the purposes of the application part there are selected and analyzed specific tools of lean manufacturing. These include for example the spaghetti diagram, the product / process matrix and the value stream mapping as the essential tool of this thesis. All this is complemented by ABC analysis. After that these methods are also applied in the practical part for solving the current project in the selected company. At first in solving the project there is dealt with the determination of the most problematic material flow between two areas of production plant. Then there is suggested the optimization solutions and all of this is also complemented by the economic evaluation of the whole project.

A competitividade de uma empresa é passível de ser construída em diferentes dimensões. Entre elas, está o modelo de gestão da produção. E, nesse sentido, destacam-se ferramentas do modelo lean. Esse modelo de produção tem sido o núcleo de numerosas iniciativas de melhoria contínua e referenciado como necessário para o aumento da competitividade das empresas. Contudo, ao considerarmos o universo das médias empresas e a implementação de um modelo de produção, realizado como um processo contínuo de melhoria, que permite estabelecer os objetivos e as capacidades da empresa, além de orientar à melhor utilização dos recursos, é pouco utilizado, e tais organizações se apresentam ineficientes na implementação de um modelo de produção que aumente sua competitividade. Partindo dessa proposição, uma empresa que adotou como modelo de gestão da produção o lean, deveria ter, também informação acerca dos benefícios das ferramentas implementadas, bem como o seu efeito sobre o desempenho produtivo. Nesse sentido, a proposta deste trabalho consiste em avaliar quais ferramentas do modelo lean foram implementadas em cinco médias empresas do segmento automotivo, em diferentes países, se houve benefícios para o processo produtivo em função da implementação e se as ferramentas foram implementadas baseadas em algum método estruturado ou não. / The competitiveness of a company is liable to be built in different dimensions. Among them, the model of production management. And in this sense we highlight the model lean tools. This production model has been the core of numerous continuous improvement initiatives and referenced as needed to increase the competitiveness of companies. However, when considering the universe of medium enterprises and a implementation of a production model, performed as a continuous process of improvement, which allows us to establish the goals and capabilities of the company, besides guiding the best use of resources, it is rarely used and such organizations present inefficient implementation of a production model that increases their competitiveness. From this proposition, a company that has adopted as a model of lean production management, should have the information about the contribution of the tools implemented, as well as its effect on performance. In this sense, the purpose of this study is to assess which model lean tools were implemented in five medium-sized companies from the automotive sector, in different countries, there are benefits to the production process due to the implementation and tools have been implemented based on a structured method or not.

Este trabalho apresenta a aplicação de uma metodologia para estudos de postos de trabalho com o objetivo de reduzir desperdícios, aplicar melhorias de layout e consequentemente melhora da ergonomia de um posto de trabalho de uma indústria do ramo automotivo, visando o diagnóstico do processo em questão, encontrando assim, oportunidades para melhoria do mesmo. Para realizar este diagnóstico e identificar as melhorias pretendidas foi utilizada a ferramenta de análise de tempo MTM (Methods-Time Measurement), técnicas de balanceamento, ergonomia e estudo de layout. Atualmente há muitas empresas no mundo que utilizam o MTM (Methods-Time Measurement), que é um sistema de tempos pré-determinados. A eliminação dos desperdícios com a finalidade da redução de tempo é necessária para o aumento da produção que será aplicado em 2012, que tem como objetivo a passagem de 29 veículos por hora para 40 veículos por hora na linha de montagem. Para o estudo de caso, foram selecionados três postos, os quais são nomeados segundo suas operações principais. O primeiro deles, Filme CAPOT, compreende a colocação de filme protetor sobre o capot do veículo na saída da linha de montagem. O segundo, Filme TETO, corresponde à colocação do mesmo filme sobre o teto do veículo. Já o Posto ECOM é onde ocorre a liberação do veículo para comercialização. Utilizando a análise de posto com as ferramentas já listadas, foi possível diminuir o tempo necessário ao operador para que mesmo realize suas atividades e assim aumentar a capacidade produtiva da empresa em 48,9%, ou seja, passa-se de 31,1 para 46,3 veículos por hora. A ergonomia do espaço de trabalho teve sua avaliação global modificada nos postos de colocação de filme de proteção no CAPOT e TETO em função da modificação do layout dos postos propiciando aos operadores menores deslocamentos e posturas de trabalho mais ergonômicas que estão abordadas no corpo do trabalho. Temse também o ganho relacionado ao espaço físico, os três postos utilizavam, juntos, 300,9m do prédio da empresa já na situação proposta necessita-se apenas de 142,6m, uma redução de 52,6%. / This paper presents the application of a methodology for studies of work stations in order to reduce waste, implement improvements to layout and consequently improves the ergonomics of a work station at automotive industry, for the diagnosis of the case in question, finding opportunities for improvement. To make this diagnosis and identify the intended improvements was used a toll for analysis of time called MTM (Methods-Time Measurement), balancing techniques, ergonomics and layout study. Currently there are many companies worldwide that use MTM (Methods-Time Measurement), which is a system of predetermined times. The elimination of waste for the purpose of reducing the time is required for the increased production to be applied in 2012, which intends the passage of 29 vehicles per hour for 40 vehicles per hour on the assembly line. For the case study, we selected three stations, which are named according to their main operations. The first, Filme CAPOT, comprising placing protective film on the top of the vehicle off the assembly line. The second Filme TETO corresponds to placing the same film on the ceiling of the vehicle. Finally the station ECOM is where occurs the release of the vehicle for sale. Using the work station analysis with the tools already listed, it was possible to reduce the time required for the operator to perform the same activities and increase the companys production capacity in 48.9%, from 31.1 to 46.3 vehicles per hour. The ergonomics of the workspace had his overall evaluation changed at the placing protective film on CAPOT and TETO stations, because the modifying the layout of the stations enabling operators to smaller displacements and more ergonomic working postures that are addressed in the body of the work. There is also the gain related to the physical space, the three stations used together 300.9 m of the companys building, and after proposed situation they needs only 142.6 m, a decrease of 52.6%.

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / This study proposes a production model that increases the manufacturing capacity in a small and medium-sized enterprise (SME) of garments with an aim to reduce the nonfulfillment of order deliveries. An assessment has been done and waiting times between production processes have been identified, along with defective products and inefficient work methods. This study proposes the design of a lean manufacturing model under the change management approach, whose methodology comprises five phases. In phase 0, awareness and training sessions are conducted (change management). Then, phase 1 reorganizes the work area (plant layout re-distribution and 5S) and phase 2 seeks better workload balances (line balance and Heijunka implementation). Later, phase 3 standardizes work methods (standardization). Finally, the proposed model will be validated to determine whether the selected operating tools are supported by the awareness that contributes to increasing production. © 2021, Springer Nature Switzerland AG. / Revisión por pares

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / The contribution of the metalworking sector to the gross domestic product is decreased by 8.6% in the 2017–2018 period because of problems such as high rejection rates, lead times, and raw material losses. Consequently, the sector’s production was reduced by PEN 1,200,000 while demand remained flat. Thus, this article proposes a production control model using 5S, Single-Minute Exchange of Dies, and tools such as Kanban and Constant Work-in-Progress (CONWIP) to increase the productivity of a sand casting line in a Peruvian metalworking enterprise that manufactures parts for mining on request. The improvement proposal involves the implementation of lean manufacturing tools and analyzes low productivity effects. The problems identified are typical of the Peruvian metalworking sector; thus, this study may contribute to finding possible solutions for issues faced by other enterprises. / Revisión por pares

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / The Peruvian export supply is primarily based on the segment of dressings and condiments. This paper seeks to adapt lean manufacturing tools using Poka-Yoke techniques and process standardization, which may align with existing processes to prevent production errors. This combination of tools is expected to reduce the percentage of waste generated throughout the condiment production process. Subsequent to an initial evaluation of the current method combined with the application of both the tools, 11.4% waste reduction was ultimately reported. / Revisión por pares