Simulação de processo de manufatura de caixas plásticas sob a ótica do fluxo de valor
Carregando...
Arquivos
Data
2021-06
Autores
Orientador
Jacobs, William
Banca
Título do periódico
ISSN
Título do Volume
Editor
Resumo
Muitas empresas aplicam métodos da produção enxuta visando a redução de perdas no processo produtivo, fator considerado essencial para que elas possam se manter competitivas no mercado, reduzir custos internos e agregar valor aos seus produtos. No entanto, para que seja possível diminuir as perdas, faz-se necessário identificar e analisar o fluxo do processo de manufatura utilizado. Esta monografia teve como objetivo analisar as perdas no processo de manufatura de caixas plásticas, e utilizou, para isso, o método de pesquisa dedutivo; a abordagem quali-quantitativa; metodologias de pesquisa descritiva e exploratória; procedimentos de investigação classificados como estudo de caso, pesquisa bibliográfica e pesquisa documental. Sua metodologia teve como base o mapeamento de fluxo de valor com o apoio da simulação, através da qual se apresentou o cenário atual do processo de manufatura, identificaram-se as perdas e, a partir disso, desenhou-se um mapa do estado futuro com o propósito de avaliar as possíveis melhorias no processo produtivo. Com a análise do estado atual, evidenciou-se que o produto percorre uma distância de 192,8 metros, o que corresponde a um lead time de 365.243,74 segundos desde o estoque de componentes até o armazenamento do produto acabado para posterior envio ao centro logístico, apresentando diversas perdas no processo produtivo, como: estoque, superprodução, espera, movimentação, transporte, produção de produtos defeituosos e processamento. Com a aplicação dos princípios e técnicas da produção enxuta, no estado futuro a distância percorrida pelo produto seria reduzida para 33 metros, resultando em uma redução de 28,12% no lead time, aumentando o tempo de valor agregado em 2,78% e, além disso, ocasionando a redução de dois colaboradores no processo produtivo. Com o desenvolvimento do estudo, concluiu-se que as perdas encontradas no processo produtivo impactam diretamente no tempo de lead time do produto. Essas perdas, por sua vez, estão diretamente interligadas a atividades que o recurso exerce dentro do modelo de produção utilizado pela empresa, uma vez que, no ambiente produtivo, o material está sujeito a situações dificilmente dimensionadas e que não agregam valor ao produto, como: viagem vazia, viagem carregada, ociosidade, coleta do material, bloqueio do recurso, espera pelo operador e pelo transporte. Além disso, essas perdas são potencializadas quando há a necessidade de formação de estoques intermediários. Uma alternativa proposta pelo presente estudo para reduzir essas perdas e diminuir o lead time foi a implantação do modelo produtivo baseado no fluxo contínuo.
Several companies adopt lean production methods aiming to reduce losses in the production process, which is considered essential for them to remain competitive in the market, reduce internal costs and add value to their products. However, in order to reduce losses, it is necessary to identify and analyze the flow of the manufacturing process used. This undergraduate thesis aimed to analyze the losses in the manufacturing process of plastic containers, and to this end it used a deductive research method; quali-quantitative approach; descriptive and exploratory research methodologies; and investigation procedures classified as case study, bibliographic research, and document research. Its methodology considered the value stream mapping reinforced by a simulation, through which the current scenario of the manufacturing process was presented, losses were identified, and based on that a map of the future state was prepared, with the objective of assessing possible improvements in the production process. Based on the analysis of the current state, it was observed that the product travels a distance of 192.8 meters, corresponding to a lead time of 365,243.74 seconds from the storage of the components to the storage of the finished product for subsequent transportation to the logistics center, and that there are various losses in the production process, such as: inventory, overproduction, waiting, motion, transportation, production of defective products and processing. With the implementation of lean production principles and techniques, in the future state the distance traveled by the product would be reduced to 33 meters, thus resulting in a reduction of 28.12% in lead time, an increase in value-added time by 2.78%, and a reduction of two employees in the production process. From this study, it was concluded that the losses identified in the production process directly impact the product lead time. These losses, in turn, are directly related to activities that the resource performs in the production model used by the company, since the material is subject to situations which are difficult to dimension and do not add value to the product in the production environment, such as: empty travel, loaded travel, idleness, material pick-up, resource block, wait for an operator and for transport. In addition, these losses are maximized when intermediate stocks are necessary. An alternative proposed by this study to reduce both losses and lead time was the adoption of a production model based on continuous flow.
Several companies adopt lean production methods aiming to reduce losses in the production process, which is considered essential for them to remain competitive in the market, reduce internal costs and add value to their products. However, in order to reduce losses, it is necessary to identify and analyze the flow of the manufacturing process used. This undergraduate thesis aimed to analyze the losses in the manufacturing process of plastic containers, and to this end it used a deductive research method; quali-quantitative approach; descriptive and exploratory research methodologies; and investigation procedures classified as case study, bibliographic research, and document research. Its methodology considered the value stream mapping reinforced by a simulation, through which the current scenario of the manufacturing process was presented, losses were identified, and based on that a map of the future state was prepared, with the objective of assessing possible improvements in the production process. Based on the analysis of the current state, it was observed that the product travels a distance of 192.8 meters, corresponding to a lead time of 365,243.74 seconds from the storage of the components to the storage of the finished product for subsequent transportation to the logistics center, and that there are various losses in the production process, such as: inventory, overproduction, waiting, motion, transportation, production of defective products and processing. With the implementation of lean production principles and techniques, in the future state the distance traveled by the product would be reduced to 33 meters, thus resulting in a reduction of 28.12% in lead time, an increase in value-added time by 2.78%, and a reduction of two employees in the production process. From this study, it was concluded that the losses identified in the production process directly impact the product lead time. These losses, in turn, are directly related to activities that the resource performs in the production model used by the company, since the material is subject to situations which are difficult to dimension and do not add value to the product in the production environment, such as: empty travel, loaded travel, idleness, material pick-up, resource block, wait for an operator and for transport. In addition, these losses are maximized when intermediate stocks are necessary. An alternative proposed by this study to reduce both losses and lead time was the adoption of a production model based on continuous flow.
Descrição
Palavras-chave
Sistema Toyota de produção; Produção enxuta; Modelo computacional; Toyota production system; Lean production; Computational model
Citação
PEDRETTI, Jórdan. Simulação de processo de manufatura de caixas plásticas sob a ótica do fluxo de valor. 2021. Monografia (Graduação em Engenharia de Produção) – Universidade do Vale do Taquari - Univates, Lajeado, 05 jul. 2021. Disponível em: http://hdl.handle.net/10737/3234.