Lean na gestão de fluxos logísticos da Dorel Portugal, Lda.

O presente trabalho debruça-se sobre a análise de fluxos de informação e materiais na empresa Dorel Portugal, Lda.. Mais concretamente, são analisados os fluxos de transmissão de informação e os fluxos de movimentação de materiais nos duais fornecedores/armazém e armazém/setor de montagem. O estudo referido terá como propósito a identificação de elementos, associados ao estado atual, passíveis e/ou carentes de melhoria. Identificados e nomeados os pontos de intervenção, desenvolvem-se propostas de solução, as quais assentam predominantemente nos princípios e ferramentas que se associam à filosofia Lean. A escolha desta filosofia, para fundamentação de propostas, prende-se com o facto de a mesma assentar numa lógica de criação de valor pela melhoria de processo, o que espelha bem a intensão subjacente a este exercício. Foram implementadas as sugestões apresentadas e validadas junto da entidade alvo de estudo. No seguimento das implementações realizadas foi executada uma análise que permite enaltecer o ganho, seja de forma quantitativa ou qualitativa, a fim de criar impacto e sensibilizar para a importância das ações executadas. Para finalizar, importa demarcar a criação de um plano de controlo, contemplado nas ações levadas a cabo, o qual é direcionado para a manutenção do processo e concretização de medidas de melhoria contínua.

Gestão documental na logística

Dissertação apresentada ao Instituto Politécnico do Porto para obtenção do Grau de Mestre em Logística Orientada por: Professor Doutor José António Baptista da Costa Coorientada por: Dr. Lourenço Fernando Gomes Pinheiro

Global material analysis on phosphorus flows, supply horizon and impact assessment on phosphorus depletion

Different problems are daily discuss on environmental aspects such acid rain, eutrophication, global warming and an others problems. Rarely do we find some discussions about phosphorus problematic. Through the years the phosphorus as been a real problem and must be more discussed. On this thesis was done a global material flow analysis of phosphorus, based on data from the year 2004, the production of phosphate rock in that year was 18.9 million tones, almost this amount it was used as fertilizer on the soil and the plants only can uptake, on average, 20% of the input of fertilizer to grow up, the remainder is lost for the phosphorus soil. In the phosphorus soil there is equilibrium between the phosphorus available to uptake from the plants and the phosphorus associate with other compounds, this equilibrium depends of the kind of soil and is related with the soil pH. A reserve inventory was done and we have 15,000 million tones as reserve, the amount that is economical available. The reserve base is estimated in 47,000 million tones. The major reserves can be found in Morocco and Western Sahara, United Sates, China and South Africa. The reserve estimated in 2009 was 15,000 million tone of phosphate rock or 1,963 million tone of P. If every year the mined phosphate rock is around 22 Mt/yr (phosphorus production on 2008 USGS 2009), and each year the consumption of phosphorus increases because of the food demand, the reserves of phosphate rock will be finished in about 90 years, or maybe even less. About the value/impact assessment was done a qualitative analysis, if on the future we don’t have more phosphate rock to produce fertilizers, it is expected a drop on the crops yields, each depends of the kind of the soil and the impact on the humans feed and animal production will not be a relevant problem. We can recovery phosphorus from different waste streams such as ploughing crop residues back into the soil, Food processing plants and food retailers, Human and animal excreta, Meat and bone meal, Manure fibre, Sewage sludge and wastewater. Some of these examples are developed in the paper.

Energy efficient scheduling for cluster-tree wireless sensor networks with time-bounded data flows: application to IEEE 802.15.4/ZigBee

Cluster scheduling and collision avoidance are crucial issues in large-scale cluster-tree Wireless Sensor Networks (WSNs). The paper presents a methodology that provides a Time Division Cluster Scheduling (TDCS) mechanism based on the cyclic extension of RCPS/TC (Resource Constrained Project Scheduling with Temporal Constraints) problem for a cluster-tree WSN, assuming bounded communication errors. The objective is to meet all end-to-end deadlines of a predefined set of time-bounded data flows while minimizing the energy consumption of the nodes by setting the TDCS period as long as possible. Sinceeach cluster is active only once during the period, the end-to-end delay of a given flow may span over several periods when there are the flows with opposite direction. The scheduling tool enables system designers to efficiently configure all required parameters of the IEEE 802.15.4/ZigBee beaconenabled cluster-tree WSNs in the network design time. The performance evaluation of thescheduling tool shows that the problems with dozens of nodes can be solved while using optimal solvers.

Simulation study of energy efficient scheduling for IEEE 802.15.4/ZigBee cluster-treeWireless Sensor Networks with time-bounded data flows

The simulation analysis is important approach to developing and evaluating the systems in terms of development time and cost. This paper demonstrates the application of Time Division Cluster Scheduling (TDCS) tool for the configuration of IEEE 802.15.4/ZigBee beaconenabled cluster-tree WSNs using the simulation analysis, as an illustrative example that confirms the practical applicability of the tool. The simulation study analyses how the number of retransmissions impacts the reliability of data transmission, the energy consumption of the nodes and the end-to-end communication delay, based on the simulation model that was implemented in the Opnet Modeler. The configuration parameters of the network are obtained directly from the TDCS tool. The simulation results show that the number of retransmissions impacts the reliability, the energy consumption and the end-to-end delay, in a way that improving the one may degrade the others.

Otimização de uma cadeia de logística interna

Atualmente qualquer organização que se queira manter no ativo, tem que obrigatoriamente inovar, reduzir o desperdício associado ao processo produtivo e simultaneamente simplificar as tarefas diárias dos seus colaboradores. E é sobre estes princípios que este trabalho é baseado, ou seja, pretende-se através da aplicação de ferramentas Lean, a melhoria contínua do processo de produção da Schmitt Elevadores. Numa fase inicial foi necessário um estudo dos diferentes fluxos de materiais, que permitiu a conceção do VSM (Value Stream Mapping). O VSM juntamente com o diagrama de Spaghetti permitiram a identificação de algumas das fontes de desperdício, relacionadas essencialmente com o excesso de movimentações. Considerando o âmbito do estágio, logística interna, e reunidas as causas de desperdício verificadas nesta área, procedeu-se à criação de um ciclo de entrega de materiais, por parte do operador logístico, baseado no conceito de milk run. Verificaram-se também problemas ao nível da gestão de stocks, pelo que também foi necessária intervenção nesta área. A aplicação das medidas mencionadas anteriormente irá traduzir-se em ganhos para o processo produtivo, nomeadamente, na criação de rotinas para os operadores logísticos; evitar deslocações por parte dos operadores de cada processo e manter em supermercado a quantidade suficiente de cada artigo, para fazer face à variabilidade da procura.

Development of procedures for the simulation of atmospheric flows over complex terrain, using OpenFOAM

The main purpose of this work was the development of procedures for the simulation of atmospheric ows over complex terrain, using OpenFOAM. For this aim, tools and procedures were developed apart from this code for the preprocessing and data extraction, which were thereafter applied in the simulation of a real case. For the generation of the computational domain, a systematic method able to translate the terrain elevation model to a native OpenFOAM format (blockMeshDict) was developed. The outcome was a structured mesh, in which the user has the ability to de ne the number of control volumes and its dimensions. With this procedure, the di culties of case set up and the high computation computational e ort reported in literature associated to the use of snappyHexMesh, the OpenFOAM resource explored until then for the accomplishment of this task, were considered to be overwhelmed. Developed procedures for the generation of boundary conditions allowed for the automatic creation of idealized inlet vertical pro les, de nition of wall functions boundary conditions and the calculation of internal eld rst guesses for the iterative solution process, having as input experimental data supplied by the user. The applicability of the generated boundary conditions was limited to the simulation of turbulent, steady-state, incompressible and neutrally strati ed atmospheric ows, always recurring to RaNS (Reynolds-averaged Navier-Stokes) models. For the modelling of terrain roughness, the developed procedure allowed to the user the de nition of idealized conditions, like an uniform aerodynamic roughness length or making its value variable as a function of topography characteristic values, or the using of real site data, and it was complemented by the development of techniques for the visual inspection of generated roughness maps. The absence and the non inclusion of a forest canopy model limited the applicability of this procedure to low aerodynamic roughness lengths. The developed tools and procedures were then applied in the simulation of a neutrally strati ed atmospheric ow over the Askervein hill. In the performed simulations was evaluated the solution sensibility to di erent convection schemes, mesh dimensions, ground roughness and formulations of the k - ε and k - ω models. When compared to experimental data, calculated values showed a good agreement of speed-up in hill top and lee side, with a relative error of less than 10% at a height of 10 m above ground level. Turbulent kinetic energy was considered to be well simulated in the hill windward and hill top, and grossly predicted in the lee side, where a zone of ow separation was also identi ed. Despite the need of more work to evaluate the importance of the downstream recirculation zone in the quality of gathered results, the agreement between the calculated and experimental values and the OpenFOAM sensibility to the tested parameters were considered to be generally in line with the simulations presented in the reviewed bibliographic sources.

Gestão de stocks e armazém de matérias-primas

Relatório de Estágio apresentado ao Instituto Politécnico do Porto para obtenção do Grau de Mestre em Logística Orientadores do Instituto: Professor Doutor Luís Barreto e Mestre Jonas Lima Orientador da empresa: Engenheiro Vítor Carvalho

Lean applied to logistics: a case study

This project aims to study the implementation of Lean principles and tools in several levels of logistics, from internal logistics to interface with distribution center and suppliers, in an industrial plant. The main focus of all efforts is to create the conditions to approach the continuous flow scenario in the manufacturing processes. The subject of improvement actions is a company whose core activity is car seat production, more specifically the car seat cover production and assembly. This focuses the assembly process, which requires the usage of a considerable variety of components and therefore is an important obstacle to the implementation of continuous flow. The most salient issues are related with inefficient interaction between sections and late supply of components in assembly lines, forcing the operator to abandon his work station and leading to production interruption. As an operational methodology, actions from Lean philosophy and optimization were implemented according to project management principles.