Identificação de boas práticas e dificuldades do SMED aplicado em uma indústria do ramo de cosméticos

The cosmetic industry has presenting growth in Brazil and one way to support this demand is improving production and reducing waste. Wastes can be related to setup time, which is spent to support demand of product´s mix and volume. One of the methodologies used to reduce setup time is SMED (Single Minute Exchange of Die). This paper aims to describe and analyze the setup process in a production line in a cosmetic industrial branch, before and after the application of SMED methodology, highlighting good practices and difficulties in order to help other companies develop fast setup. The research method used was the case study. From the analysis of the implementation of the methodology on the company which is object from the case study was possible to summarize good practices, such as: the use of pillar E&T to store information about the training on the SMED methodology; creation of a multifunctional teamwork and involving different areas; creation of a “From-To” matrix. Difficulties were identified, such as: high and constant turnover of people who work on the shop floor; lack of discipline in filling the forms and by doing the setup activities that were standardized; lack of financial resources; lack of people´s availability in orer to conduct necessary meetings and trainings. Recommendations for other companies have also been proposed, such as: training of the team involved, before starting the project and a refresher training; standardization of training, forms and documentation of all steps of the project; create a multifunctional team; training after an employee, who is responsible for the setup, leaves the company

Implementação da metodologia TPM em uma indústria do setor de higiene pessoal, saúde e beleza

This work presents a project of Action Search in a consumption industry of the sector of personal care, health and beauty. Following the implementation steps of Autonomous Maintenance Pillar of TPM methodology, stands for Total Productive Maintenance, this work aims to ensure the advancement of some machines in a production line of the company to the next steps of the methodology implementation, demonstrating the results achieved by the TPM. In the company in question, the TPM has been implemented in the past but lost strength over the years and some of its concepts were abandoned, producing then a drop in the equipments efficiency, increased wastes and breaks in the processes, as well as loss in product quality. Then, the need arose to restart the implementation process from the beginning, to strictly follow all the steps of the methodology, ensuring increased efficiency of equipment and processes. Through training and a changing in the company culture, it was possible a joint effort between Operation and Maintenance in order to enhance the knowledge of the operators on their machines. Initially, it was developed a general cleanliness program of equipments so that it could be possible to find the anomalies in the process. Subsequently, operators and maintainers were trained to detect anomalies, enabling equipments to work under their basic conditions of operation and subsequently building provisional standards of equipment cleaning, lubrication and inspection. Through the improvement presented by some indicators such as OEE, wastes, bankruptcies and unavailability, it was proved the importance and the positive effects of TPM implementation in manufacturing

Redução de tempo de setup de uma máquina de encartuchamento pela técnica SMED

Currently the market requires companies to adapt for they can have the lowest possible cost in their manufacturing, be it a good or service, thus obtaining a greater profit. For this profit the Toyota Production System applies lean manufacturing practices actions with reduced spending, smaller lots and stocks, generated by market demand. The technique allows SMED with few actions, changes and investments that time does not exceed one digit on your total time. This case study shows that only with standardization and use of inexpensive improvements, could reduce setup time on a machine for 70 minutes to time of approximately 48 minutes with little investment, demonstrating the viability of the tool presented

Misclassification probability as obese or lean in hypercaloric and normocaloric diet

The aim of the present study was to determine the classification error probabilities, as lean or obese, in hypercaloric diet-induced obesity, which depends on the variable used to characterize animal obesity. In addition, the misclassification probabilities in animals submitted to normocaloric diet were also evaluated. Male Wistar rats were randomly distributed into two groups: normal diet (ND; n=3 1; 3,5 Kcal/g) and hypercaloric diet (HD; n=31; 4,6 Kcal/g). The ND group received commercial Labina rat feed and HD animals a cycle of five hypercaloric diets for a 14-week period. The variables analysed were body weight, body composition, body weight to length ratio, Lee index, body mass index and misclassification probability A 5% significance level was used. The hypercaloric pellet-diet cycle promoted increase of body weight, carcass fat, body weight to length ratio and Lee index. The total misclassification probabilities ranged from 19.21 % to 40.91 %. In Conclusion, the results of this experiment show that rnisclassification probabilities Occur when dietary manipulation is used to promote obesity in animals. This misjudgement ranges from 19.49% to 40.52% in hypercaloric diet and 18.94% to 41.30% in normocaloric diet.

Environmental management and operational performance in automotive companies in Brazil: The role of human resource management and lean manufacturing

The main objective of this study is to verify the influence of Environmental Management (EM) on Operational Performance (OP) in Brazilian automotive companies, analyzing whether Lean Manufacturing (LM) and Human Resources (HR) interfere in the greening of these companies. Therefore, a conceptual framework listing these concepts was proposed, and three research hypotheses were presented. A questionnaire was elaborated based on this theoretical background and sent to respondents occupying the highest positions in the production/operations areas of Brazilian automotive companies. The data, collected from 75 companies, were analyzed using structural equation modeling. The main results are as follows: (a) the model tested revealed an adequate goodness of fit, showing that overall, the relations proposed between EM and OP and between HR, LM and EM tend to be statistically valid; (b) EM tends to influence OP in a positive and statistically weak manner; (c) LM has a greater influence on EM when compared to the influence HR has over EM; (d) HR has a positive relationship over EM, but the statistical significance of this relationship is less than that of the other evaluated relationships. The originality of this paper lies in its gathering the concepts of EM, LM, HR and OP in a single study, as they generally tend not to be treated jointly. This paper also provided valid empirical evidence for a littlestudied context: the Brazilian automotive sector. © 2012 Elsevier Ltd. All rights reserved.

Lean and green? Evidências empíricas do setor automotivo brasileiro

The aim of this paper is to verify whether the practices of lean manufacturing are positively associated with the adoption of environmental management practices in Brazilian companies in the automotive sector to test the hypothesis that by being lean the business tends to become green. To this purpose, a framework associating these concepts with the research hypothesis was proposed. The data collected from 75 companies were analyzed using Structural Equation Modeling. The main results show that lean manufacturing (LM) is positively associated with environmental management (EM), but the explanation power of LM over EM is considered weak/moderate. In fact, being lean also means being green, but other organizational variables not considered in this study may influence the greening of organizations.

Integração dos programas de melhoria Lean Manufacturing e Six Sigma aplicados à logística de transporte de produtos de uma indústria metalúrgica

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Otimização do processo de MRP (Material Requirement Planning) de embalagens: uma aplicação da metodologia lean six sigma em uma indústria de agronegócios

There is a growing search for continuous improvement within the companies which creates an obligation of reducing and when it is possible eliminating waste. Production Planning and Control Department (PCP) is not out of this question, making necessary the application of methods and creation of tools that eliminate steps which do not add value to the planning process. This paper aims to develop a tool which concentrates in just one place all the necessary information to make the packaging material requirement planning (MRP) in a agribusiness company. Besides, it also aims, in a more visual way and using devices that prevent mistakes (Poka-Yoke), to reduce the number of reviews and mistakes made by analysts. As a result, an Excel spreadsheet was developed. This spreadsheet shows what happens with the status of planning and receiving of packaging, giving some advices when some critical situation happens. The use of Lean Manufacturing Method and the action research method helped to well define the problem and to reduce the number of steps, spreadsheets and time of process in 80%, 60% and 75%, respectively

Lean six sigma como estratégia para o aumento de eficiência em laminação de alumínio

This study aims to assess the implementation of Lean Six Sigma in the preparation of plates and hot lamination process for a company of aluminum rolled products, to improve the quality, productivity and process efficiency. As a basis for achieving these goals, the DMAIC methodology and various quality tools such as Cause Effect Diagram, Process Flow, SIPOC, Pareto, FMEA and Control Chart were used, trying to propose improvements to processes and increase their efficiency. The results were significant and were the basis for the continuation of a continuous improvement project throughout the factory

Lean Six sigma aplicado a uma empresa do setor de embalagens

With the advent of a global economy, Lean Six Sigma meets the demand of new production process that creates products within the customer’s specification without any wastage. The objectives of this work is to use the concepts Lean Manufacturing and Six Sigma parallel to minimize costs, increase the customer base, reduce the delivery time which implies an increase in the turnover of products on the shelves in a packaging company. We used the DMAIC method to continue working. The method DMAIC indicated the main failure modes that were fixed in the step improve. At this stage the tools of Lean Manufacturing gain tremendous value by optimizing processes with defects. The conclusion involves an increase in monthly billing, a corporate restructuring and, finally, a renewal in how to conduct the work of management

Aplicação do lean six sigma na linha de produção de turbinas industriais a vapor

This work evaluates the implementation of Lean Six Sigma into the Steam Turbine’s Blades Manufacturing Process, aiming to improve productivity, quality and operational efficiency. Therefore, several tools have been applied, such as VSM, Spaghetti Diagram, Ishikawa, Pareto, DMAIC, Benchmarking and Control Charts, seeking to propose process improvements, as well as Quality Indicators creation. It was obtained a significant waste reduction throughout the process, achieving a lead time reduction of 42% and 83,41% in transport. Also, were introduced the Lean Thinking concepts, such as pull production and Continuous material flow. At the same time, it was possible to calculate the process capability and the sigma level, evaluating and proposing some improvements

Implementação da eficiência global de equipamento (OEE) no padrão de produção e análise de impactos

Nowadays, there is a need for improvements in production processes for companies to be competitive, as it is an obligation of businesses, it is necessary to know about the production processes accurately, to learn where improvements in work and thus have large impacts results. The calculation of efficiency of production lines is necessary to know as much about the progress of production and for product costing, when the measurement is not suitable, it generates negative impacts on the company. Due to the impact generated by this parameter, the graduation work carry out the study of change in a method that does not include all requirements necessary, by another method known as Overall Equipment Effectiveness, and according to studies, covering various parameters, showing become more consistent. These values are contained in the pattern production which is used to fund the product, thereby also occur financial impacts. Thus the work will study the change along with the analysis of impacts caused by the change

Padronização das atividades de manutenção para implementação de um projeto de TPM

La mission de ce rapport se trouvée dans un projet major de mise en place de la TPM dans l’usine de Biotechnologie à Huningue. Le même sera utilisé comme pilote pour les autres sites de l’entreprise. Le but spécifique de ma mission au sein de Novartis, était d’identifier les activités principales des équipes de maintenance, étudier la façon de travailler et la manière comment ils étaient renseignées dans leurs Ordres de Travail (OT). Ensuite, proposer un standard de flux de travail et façon de renseigner les OT et ainsi organiser la façon de travailler et pouvoir planifier les activités de maintenance, ayant une bonne base de données pour faire les indicateurs