Navegando por Assunto "Kaizen"

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Acesso aberto (Open Access)
Aplicação de ferramentas de manufatura enxuta em processo de montagem de motocicletas no Pólo Industrial de Manaus
(Universidade Federal do Pará, 2020-02-12) DIMARIO, Raphael Kinzu; QUARESMA, João Nazareno Nonato; http://lattes.cnpq.br/7826389991864785; https://orcid.org/0000-0001-9365-7498
The target of this research is highlight the application of Lean Manufacturing tools in motorcycle assembly process. Productivity increase, line stoppage control and 5S methodology are expected to be improved. Specifically, the entire production flow was mapped and Lean tools were chosen to be implemented in the shop floor. Also, key performance indicators were used as the way to show and share all improvements and benefits reached. Lean manufacturing is a production system focused to identify and maximize the added value of the products based on wastes reduction including value stream map, standardization and 5S.The project was developed starting from the literature research and case study. Direct observation in the shop floor collecting all data and analysis of them made part of this study. Regarding data, were collected the cycle time of all process, material flow and 5S status of the area. Significant achievements were reached during and in the end of this project. It was increased 15% of 5S score. Line stoppage was reduced by 52% with important actions like standardization and homologation of new method of material control. Significant increase of 37.5% in productivity and capacity raised the company to the next level. As indirect result is worth to mention a reduction of R$9,900/year in extra shipments due to material control improvement.
Acesso aberto (Open Access)
Implantação de um novo layout de uma linha de montagem de motocicletas estruturados a partir da metodologia MASP e ferramentas Lean manufacturing
(Universidade Federal do Pará, 2021-05-04) OLIVEIRA, Edyones Barros de; MAGNO, Rui Nelson Otoni; http://lattes.cnpq.br/9017163598972975
This study aims to approach the implementation of a new layout of manufacturing process for high displacement motorcycles using the MASP methodology and Lean Manufacturing tools as a facilitator to adapt to the market oscillation. The research was carried out in a motorcycle industry located in the Free Trade Zone of Manaus, using the PDCA method (Plan, Do, Check, Action) for the feasibility after SWOT analysis (Strengths, Weaknesses, Opportunities, Threats) in which the focus of actions of the project was defined. As a result, benefits were presented, such as: flexibility to increase production capacity due to the new layout arrangement and 67% reduction of Work In Process that made 25% of the total industrial area viable; versatility in the assembly process due to increased training of operators to produce all models; 5,5% reduction of the operator quantity keeping the same productive capacity; a reduction of at least 25% in the investment needed to implement new products, reaching up to 60% depending on the motorcycle in question, enabling the approval of the launch of four models in the last six months and avoiding an increase of 51.25% in value the asset chart; annual reduction of R$ 80,000.00 in costs with spare parts and preventive maintenance service; 15% reduction in electricity consumption; and a 5% decrease in line stoppage due to the limitation to change the production plan. With that, it provided greater brand competitiveness in the Brazilian market even when compared to other brands in thex same segment that have already presented studies of process optimization focused on the Lean Production principle but limited to the manufacturing benefits.