Melhoria do abastecimento interno com comboio logístico na indústria automével

Este projeto surgiu da necessidade de uma empresa da indústria automóvel melhorar o modo de abastecimento das suas várias linhas de produção. Optando por um abastecimento através de comboio logístico, em detrimento do uso de empilhador, indo assim de encontro com as práticas de pensamento lean aplicadas à logística, procurando eliminar o desperdício e aumentar a produtividade de uma ação vital do seu negócio. Nesse sentido, este projeto procurou dar resposta a esse objetivo, consistindo no estudo da situação atual e posterior análise das alterações necessárias a realizar visando a melhoria do abastecimento interno com comboio logístico. O projeto integra diversas reformulações ao nível das linhas de produção, armazém e de todo o planeamento logístico de abastecimento. Ao aplicar as mudanças e os novos planeamentos de abastecimento propostos são esperados resultados de vários ganhos a três grandes níveis: Recursos Humanos, Materiais e Ambientais.

Vaness: DNS for nomadic users in vehicular networks

Vehicular networks, also known as VANETs, are an ad-hoc network formed by vehicles and road-side units. Nowadays they have been attracting big interest both from researchers as from the automotive industry. With the upcoming of automotive specific operating systems and self-driving cars, the use of applications on vehicles and the integration with common mobile devices is becoming a big part of VANETs. Although many advances have been made on this field, there is still a big discrepancy between the communication layer services provided by VANETs and the user level services, namely those accessible through mobile applications on other networks and technologies. Users and developers are accustomed to user-to-user or user-tobusiness communication without explicit concerns related with the available communication transport layer. Such is not possible in VANETs since people may use more than one vehicle. However, to send a message to a specific user in these networks, there is a need to know the ID of the vehicle where the user is, meaning that there is a lack of services that map each individual user to VANETs endpoint (vehicle identification). This dissertation work proposes VANESS, a naming service as a resource to support user-to-user communication within a heterogeneous scenario comprising typical ISP scenario and VANETs focused on mobile devices. The proposed system is able to map the user to an end point either locally (i.e. there is not internet connection at all), online (i.e. system is not in a vehicular network but has direct internet connection) and using a gateway (i.e. the system is in a vehicular network where some of the nodes have internet access and will act as a gateway). VANESS was fully implemented on android OS with results proving his viability, and partially on iOS showing its multiplatform capabilities.

Development of variable displacement oil pump for internal combustion engines

In the last years the need to develop more environmentally friendly and efficient cars as led to the development of several technologies to improve the performance of internal combustion engines, a large part of the innovations are focused in the auxiliary systems of the engine, including, the oil pump, this is an element of great importance in the dynamics of the engine as well a considerable energy consumer. Most solutions for oil pumps to this day are fixed displacement, for medium and high speeds, the pump flow rate is higher than the needs of the engine, this excess flow leads to the need for recirculation of the fluid which represents a waste of energy. Recently, technological advances in this area have led to the creation of variable displacement oil pumps, these have become a 'must have' due to the numerous advantages they bring, although the working principle of vane or piston pumps is relatively well known, the application of this technology for the automotive industry is new and brings new challenges. The focus of this dissertation is to develop a new concept of variable displacement system for automotive oil pumps. The main objective is to obtain a concept that is totally adaptable to existing solutions on the market (engines), both dimensionally as in performance specifications, having at the same time an innovative mechanical system for obtaining variable displacement. The developed design is a vane pump with variable displacement going in line with existing commercial solutions, however, the variation of the eccentricity commonly used to provide an variable displacement delivery is not used, the variable displacement is achieved without varying the eccentricity of the system but with a variation of the length of the pumping chamber. The principle of operation of the pump is different to existing solutions while maintaining the ability to integrate standard parts such as control valves and mechanical safety valves, the pump is compatible with commercial solutions in terms of interfaces for connection between engine systems and pump. A concept prototype of the product was obtained in order to better evaluate the validity of the concept. The developed concept represents an innovation in oil pumps design, being unique in its mechanical system for variable displacement delivery.

Implementação de ações de melhoria contínua numa empresa de fabrico de produtos eletrónicos

O projeto desenvolvido teve como principal objetivo a implementação de ações de melhoria contínua numa empresa da indústria automóvel. A indústria automóvel insere-se num ambiente muito exigente e desenvolvido o que o torna, naturalmente, num ambiente muito competitivo. A crescente concorrência mundial e a revolução da tecnologia da informação acabaram por se tornar grandes desafios e, neste contexto, cada vez mais empresas e indivíduos veem a filosofia kaizen como sendo a solução. Esta filosofia implica melhoria contínua por todos, em todos os lugares e todos os dias. No sentido de melhorar o desempenho do setor produtivo da empresa onde foi desenvolvido este trabalho, foram propostas várias ações de melhoria contínua tais como: (i) a implementação de um sistema kanban para tornar mais ágil o processo de funcionamento da linha; (ii) uma alteração de layout com a criação de um armazenamento vertical para linhas que não trabalham de forma continuada; e (iii) um programa para facilitar a análise de defeitos de alguns produtos e consequentemente melhorar a qualidade dos mesmos. O presente relatório descreve essas ações e, quando possível, o impacto das mesmas no desempenho do sistema.

Natural fibers based composites - Technical and social issues

Brazil is the only country in South America to have an automotive supplier sector based on natural fibers. New opportunities are arising due to an increase demand by the car makers in applying natural fibers in their parts. Several crop fibers have been developed in Brazil. Among them can be listed caroa, piacava, pupunha, mutum and others of regional application. For the automotive industry, which requires large quantities with uniform quality, the alternatives are sisal (170,000 ton/yr), curaua (150 ton/yr in 2003), malva, 200 ton/yr; Brazil is the single largest producer country of sisal, and commercially, the only one in curaua. For South America, the alternatives are fique in Colombia, abaca in equator, flax in Argentina and curaua in Venezuela. It must be understood by the target countries of drugs, is that crop fiber can be an economic alternative to coca in the Andes region, therefore an instrument of land reform and drug reduction plantations. Several companies have a strong program of apply natural fibers based components in their products: Volkswagen do Brazil, DaimlerChrysler, General Motors do Brazil. Among their suppliers can be listed companies such Pematec (curaua), Toro (sisal, coir and jute), Incomer (sisal and jute), Ober (jute, curaua), Indaru (jute and sisal), Antolin (imported kenaf,) Tapetes Sao Carlos (sisal), Poematec (coir) and Art-Gore, with Woodstock'' wood and natural fibers). Figures about production and demand are discussed in the paper.

SQMS – A prototype for a supplier quality management system

Within the supply chain, the customer does not simply buy parts or services from suppliers, but also buys supplier capabilities, which results in quality products and services. Having a tool that handles the Inspection as well as the Nonconformance, Complaint, Corrective Action and Concession processes is key to successfully track the supplier performance. Taking as a case study a Supplier Quality Management (SQM) currently in operation in an Original Equipment Manufacturer (OEM) for automotive industry, this paper presents a platform to support a Supplier Quality Management System (SQMS), that fits the technical specification ISO/TS 16949 requirements. This prototype is composed by a web platform and a mobile App, having flexibility and mobility as key main characteristics.

Projecto e Implementação de Sistema de Alimentação Automática para Forno de Apoio à Injecção de Zamak

A injecção de Zamak em Portugal é uma actividade corrente, sendo usada na produção de inúmeras peças de pequena dimensão, nomeadamente em acessórios de vestuário, no fabrico de cablagens metálicas para a indústria automóvel, no fabrico de placas indicativas de marcas nos mais diversos produtos, entre muitas outras aplicações. Quando a quantidade de Zamak injectada em cada ciclo é relativamente baixa, o tempo que demora a consumir um lingote é bastante longo, pelo que não se justifica que o forno esteja equipado com um sistema de alimentação automática de lingotes. No entanto, quando as peças injectadas possuem uma maior massa ou o número de cavidades por molde é maior, um lingote pode ser consumido num período de tempo suficientemente curto para ser necessário um operário permanentemente atento à alimentação do forno. Neste caso, justifica-se a inclusão de um sistema automático que vá descarregando lingotes à medida que aquele que está a abastecer o forno é consumido. O presente trabalho foi elaborado com base na necessidade de uma empresa fabricante de máquinas para a injecção de Zamak, a qual pretendia dotar alguns dos seus modelos com este sistema, indo de encontro às necessidades dos seus clientes e ampliando a gama de acessórios que passa a poder disponibilizar em torno de cada equipamento.

Resistência ao choque térmico de carbeto de silício sinterizado via fase líquida

Tese (Doutorado em Tecnologia Nuclear)

The minimum number of measurements for colour, sparkle, and graininess characterisation in gonio-apparent panels

Materials with new visual appearances have emerged over the last few years. In the automotive industry in particular there is a growing interest in materials with new effect finishes, such as metallic, pearlescent, sparkle, and graininess effects. Typically, for solid colours the mean of three measurements with repetitions is sufficient to obtain a representative measurement for colour characterisation. However, gonio-apparent panels have non-homogeneous colours, and there are no studies that recommend the minimum number of repetitions for colour, sparkle, and graininess characterisation of this type of panel. We assume that colour panels incorporating special-effect pigments in their colour recipes will require a higher minimum number of measurements than solid colour panels. Therefore, the purpose of this study is to verify this assumption by using a multiangle BYK-mac spectrophotometer, given that it is currently the only commercial device that can measure colour, sparkle, and graininess values simultaneously. In addition, a possible methodology is given for establishing the minimum number of measurements when characterising gonio-apparent materials using a specific instrument, able to be implemented in future instruments when determining multiple appearance attributes (colour, gloss, sparkle, etc.) for many coloration technologies. Thus, we studied the minimum number of measurements needed to characterise the colour, sparkle, and graininess of three types of sample with solid, metallic, and pearlescent coatings respectively. Twenty measurements were made at twenty random positions (different target areas) of 90 samples. The minimum number of measurements for all these variables was determined on the basis of the point at which the cumulative mean value became constant. Thus, applying new statistical tools, it is clearly shown that metallic and pearlescent panels require more colour measurements than solid panels, in particular when geometries are being measured in a specular direction. As regards texture (sparkle and graininess), more measurements are needed for graininess than for sparkle, and more for metallic panels than for pearlescent panels.

MODELING AND EXPERIMENTAL SETUP OF AN HCCI ENGINE

For the past three decades the automotive industry is facing two main conflicting challenges to improve fuel economy and meet emissions standards. This has driven the engineers and researchers around the world to develop engines and powertrain which can meet these two daunting challenges. Focusing on the internal combustion engines there are very few options to enhance their performance beyond the current standards without increasing the price considerably. The Homogeneous Charge Compression Ignition (HCCI) engine technology is one of the combustion techniques which has the potential to partially meet the current critical challenges including CAFE standards and stringent EPA emissions standards. HCCI works on very lean mixtures compared to current SI engines, resulting in very low combustion temperatures and ultra-low NOx emissions. These engines when controlled accurately result in ultra-low soot formation. On the other hand HCCI engines face a problem of high unburnt hydrocarbon and carbon monoxide emissions. This technology also faces acute combustion controls problem, which if not dealt properly with yields highly unfavorable operating conditions and exhaust emissions. This thesis contains two main parts. One part deals in developing an HCCI experimental setup and the other focusses on developing a grey box modelling technique to control HCCI exhaust gas emissions. The experimental part gives the complete details on modification made on the stock engine to run in HCCI mode. This part also comprises details and specifications of all the sensors, actuators and other auxiliary parts attached to the conventional SI engine in order to run and monitor the engine in SI mode and future SI-HCCI mode switching studies. In the latter part around 600 data points from two different HCCI setups for two different engines are studied. A grey-box model for emission prediction is developed. The grey box model is trained with the use of 75% data and the remaining data is used for validation purpose. An average of 70% increase in accuracy for predicting engine performance is found while using the grey-box over an empirical (black box) model during this study. The grey-box model provides a solution for the difficulty faced for real time control of an HCCI engine. The grey-box model in this thesis is the first study in literature to develop a control oriented model for predicting HCCI engine emissions for control.

Multi-objective optimization of material model parameters of an adhesive layer by using SPEA2

The usage of multi material structures in industry, especially in the automotive industry are increasing. To overcome the difficulties in joining these structures, adhesives have several benefits over traditional joining methods. Therefore, accurate simulations of the entire process of fracture including the adhesive layer is crucial. In this paper, material parameters of a previously developed meso mechanical finite element (FE) model of a thin adhesive layer are optimized using the Strength Pareto Evolutionary Algorithm (SPEA2). Objective functions are defined as the error between experimental data and simulation data. The experimental data is provided by previously performed experiments where an adhesive layer was loaded in monotonically increasing peel and shear. Two objective functions are dependent on 9 model parameters (decision variables) in total and are evaluated by running two FEsimulations, one is loading the adhesive layer in peel and the other in shear. The original study converted the two objective functions into one function that resulted in one optimal solution. In this study, however, a Pareto frontis obtained by employing the SPEA2 algorithm. Thus, more insight into the material model, objective functions, optimal solutions and decision space is acquired using the Pareto front. We compare the results and show good agreement with the experimental data.

Management of industrialization projects

Short time-to-market is a key success factor in the todays’ dynamic business environment and many companies are trying to improve their product development processes. A challenge is to develop products according to the time plan and at the same time keeping the cost low and the quality high. This study focuses on the project management within the product development process in an automotive industry. The background of this study started as a request from the research and development department at the automotive company, which led to the following questions; 1) what are the most crucial factors for project success? 2) How can these factors contribute to a more successful outcome? 3) How can project management decrease product development lead time by sharing knowledge? The research approach is a case study and the data collection consist of interviews and questioners at two companies connected to project management in product development projects. Spider charts are created from the collected data containing eleven dimensions to show similarities and differences between the project managers working within the research and development department as well as between the two companies. The main conclusions are that there is a need to allow a certain level of flexibility when managing projects, in order to more easily handle late changes. Being involved in a project from the concept phase could facilitate the product development activities later on, due to a deeper understanding regarding previous decisions. Further, knowledge sharing methods, such as databases, has to be designed to be suitable for a specific organization and user friendly which enables the users to more easily search for specific types of knowledge. Lastly, a low level on the detailed focus is shown to be another success factor, however, in some cases there is still a need of this detailed focus to solve specific problems but the details may never become a higher focus than the holistic view.

Estrategias de logística inversa que permitan la reutilización de llantas usadas

Esta investigación busca desde la logística inversa, mostrar como un producto tan implementado y desechado por la sociedad, puede generar un nuevo uso, e incluso la reintegración total de sus materias primas a la cadena de suministro, mostrando la estrecha relación que existe entre la logística inversa y la reutilización de productos fuera de uso. Para esto se analizara el manejo actual que tienen las llantas en Bogotá, planteando su flujo y dando a conocer el principal punto de falencia, que es la recolección y los diferentes sitios de acopio de estas. Los neumáticos o llantas son desechados anualmente en Bogotá sin medir las consecuencias ambientales que esto trae consigo, pues las quemas a cielo abierto de estos materiales y su almacenamiento inadecuado generan altos riesgos para su entorno y el medio ambiente. Además, el manejo inapropiado de llantas es una de las principales razones por la cual pasan a ser obsoletas al poco tiempo de uso. El proceso de fabricación de llantas es muy similar al proceso de cualquier producto, pues en resumen este cuenta con la implementación de sus materias primas, proceso de manufactura, una inspección final y como resultado un producto terminado, que al ser vendido muchas compañías se libran de la disposición final de las llantas. Pero ahí radica un punto a favor para la logística inversa, donde esta buscara la manera de darle un nuevo ciclo de vida a este producto, a través del reciclaje y la reutilización. Mediante esta investigación, se busca captar los principales lugares de acopio de llantas usadas en Bogotá, de manera que estos serán nuestros principales puntos de información para el proyecto, que permita plantear y definir de manera clara estrategias y conclusiones cualitativas.

Trastornos musculoesqueléticos en trabajadores de la industria automotriz: revisión de la literatura 2000 a 2016.

Los trastornos musculoesqueléticos (TME) tienen alta relación con la industria automotriz afectando a los trabajadores en quienes se puede encontrar varias patologías como Síndrome Del Túnel Del Carpo, Epicondilitis, Síndrome del Manguito Rotador, discopatía lumbar y lumbalgias, entre otros. Entre los factores de riesgo asociados a estos trastornos están los movimientos repetitivos, posturas inadecuadas, vibración, uso manual de herramientas, tareas físicas demandantes y el mal levantamiento de pesos. Todas estas patologías son causa de ausentismo laboral en todo el mundo, lo que conlleva a un aumento en el costo económico por incapacidades, ayudas diagnósticas y tratamientos. Se realizó una revisión de la literatura científica de artículos publicados del año 2000 a 2016 con relación a los trastornos musculoesqueléticos en la industria automotriz en las bases de datos de Pubmed, Ebsco Host, ScienceDirect y Embase. La evidencia encontrada sugiere que la patología lumbar es la que presenta mayor prevalencia en la industria, con 65% en la población Europea, 42% en Asia, Norteamérica en un 20% y en América Latina en un 46%. A pesar que en la industria automotriz predominan como fuerza laboral los hombres, se reportó que las mujeres eran las que tenían mayores factores de riesgo para desarrollar un TME y dentro de estos las posturas inadecuadas, movimientos repetitivos, sobrecarga laboral y levantamiento de pesos, sumado al tiempo de exposición que fue un común denominador en cada uno de los estudios analizados. Las conclusiones fueron que la prevalencia de TME en esta industria es elevada y esto amerita la implementación de programas de prevención más enfocados en este tema. Además no se encontró en la literatura la existencia de un método eficiente para análisis postural y de sobrecarga física, lo que habla de una necesidad urgente de realizar más investigaciones enfocadas en este tipo de población.

La construcción de sentido (‘sensemaking’) de un entorno estratégico turbulento por parte de los altos directivos: un estudio en una multinacional automotriz

Este artículo presenta los resultados de una investigación realizada al interior de dos contextos. Por un lado, el teórico, en el marco de uno de los discursos más relevantes en los campos de la estrategia organizacional, de la managerial and organizational cognition (MOC) y, en general, de los estudios organizacionales (organization studies): la construcción de sentido (sensemaking). Por el otro, el empírico, en una de las grandes compañías multinacionales del sector automotriz con presencia global. Esta corporación enfrenta una permanente tensión entre lo que dicta la casa matriz, en relación con el cumplimiento de metas y estándares específicos, considerando el mundo entero, y los retos que, teniendo en cuenta lo regional y lo local, experimentan los altos directivos encargados de hacer prosperar la empresa en estos lugares. La aproximación implementada fue cualitativa. Esto en atención a la naturaleza de la problemática abordada y la tradición del campo. Los resultados permiten ampliar el actual nivel de comprensión acerca de los procesos de sensemaking de los altos directivos al enfrentar un entorno estratégico turbulento.