Melhoria de eficiência de máquinas pela metodologia DMAIC em eventos Kaizen

In a highly competitive and globally integrated market, excellence in production processes has become a survival factor, instead of just a differential point. In this context, companies from various sectors have resorted to philosophies and techniques already established in the literature to improve the efficiency of their production processes. This paper discusses aspects and techniques used to improve the production efficiency of a multinational company that manufactures surgical devices to a global market. Through DMAIC methodology, there were found opportunities to improve machines' efficiency by OEE, an efficiency indicator, in Kaizen Events. A case study was conducted to analyze the methodology and to identify good practices and difficulties along the way

Riduzione delle perdite e incremento dell'indice OEE di un'isola di lavoro mediante l'applicazione di metodologie SMED e TPM

Questo elaborato nasce da uno stage presso lo stabilimento Bonfiglioli Trasmital S.p.A. di Forlì, un’azienda manifatturiera specializzata nella produzione, costruzione e distribuzione di motoriduttori di velocità, sistemi di azionamento e motoriduttori epicicloidali applicati nel campo industriale, dell’automazione, delle macchine movimento terra e nell’ambito delle energie alternative. Il progetto ha lo scopo di aumentare la disponibilità di un impianto di tempra ad induzione. La scelta di tale impianto quale oggetto dell’attività, proviene da un’analisi delle ore di disponibilità perse per inefficienza, nell’anno 2012, in tutto il reparto di lavorazione meccanica dello stabilimento produttivo di Forlì e dall’analisi dell’OEE (Overall equipment effectiveness), indicatore principale per stabilire l’efficienza di un impianto. Analizzando la natura delle perdite del macchinario, tipicamente guasti, micro fermate e setup, si è deciso di applicare le tecniche di TPM e dello SMED: il TPM (Total Productive Maintenance) persegue l’obiettivo di migliorare la produttività degli impianti e la loro efficacia, grazie alla riduzione delle cause di perdita ricercando il miglioramento continuo del processo di produzione e della qualità, mentre lo SMED (Single-Minute Exchange of Die) è una metodologia volta alla riduzione dei tempi di cambio produzione; la grande innovazione di tale teoria risiede nella possibilità di ridurre fortemente i tempi impiegati per effettuare un’operazione di setup con un solo digit ossia in un lasso di tempo inferiore a dieci minuti.

Aplicação de metedologias Lean e 6-Sigma em unidade de restauração coletiva - um estudo de caso

As unidades de restauração coletiva dos Serviços de Ação Social (SAS) do Instituto Politécnico de Viana do Castelo (IPVC) têm desenvolvido um esforço para a aplicação de metodologias de Gestão que melhorem a sua eficiência e consequente competitividade. A metodologia 6-Sigma tem como foco a diminuição ou eliminação da incidência de erros ou defeitos num processo. A metodologia Lean tem como objetivo o aumento da produtividade, reduzindo desperdícios e gerando valor. Por conseguinte, o objetivo do presente trabalho consistiu na adoção destas metodologias de trabalho. Aplicou-se a metodologia 6-Sigma ao departamento de receção e aprovisionamento das matérias-primas, de forma a incrementar e agilizar a avaliação de fornecedores, melhorar o desempenho e racionalizar os recursos deste departamento dos SAS da Escola Superior de Tecnologia e Gestão (ESTG) do IPVC. A implementação da filosofia Lean 6-Sigma foi aplicada nas zonas de atendimento e distribuição de refeições prontas, com vista a medir o impacto da flutuação e disponibilidade dos recursos humanos afetos ao serviço de cantinas dos SAS, apoiando o serviço de refeições com qualidade e segurança alimentar, e contribuindo para uma maior eficiência do serviço. A metodologia seguida na investigação e análise deste trabalho segue os objetivos de cada fase do DMAIC (De f i n e, Me a s u r e, Analyse, Improve, Check) segundo a American Society for Quality (ASQ). O estudo permite concluir que as propostas de melhoria verificadas assentam na diminuição de defeitos e desperdícios, logo um aumento da qualidade dos serviços prestados pela organização

Analisi multi-obiettivo in ottica lean-green della reverse logistics dei veicoli a fine vita (ELV)

La gestione del fine vita dei prodotti è un argomento di interesse attuale per le aziende; sempre più spesso l’imprese non possono più esimersi dall’implementare un efficiente sistema di Reverse Logistics. Per rispondere efficacemente a queste nuove esigenze diventa fondamentale ampliare i tradizionali sistemi logistici verso tutte quelle attività svolte all’interno della Reverse Logitics. Una gestione efficace ed efficiente dell’intera supply chain è un aspetto di primaria importanza per un’azienda ed incide notevolmente sulla sua competitività; proprio per perseguire questo obiettivo, sempre più aziende promuovono politiche di gestione delle supply chain sia Lean che Green. L’obiettivo di questo lavoro, nato dalle esigenze descritte sopra, è quello di applicare un modello innovativo che consideri sia politiche di gestione Lean, che dualmente politiche Green, alla gestione di una supply chain del settore automotive, comprendente anche le attività di gestione dei veicoli fuori uso (ELV). Si è analizzato per prima cosa i principi base e gli strumenti utilizzati per l’applicazione della Lean Production e del Green supply chain management e in seguito si è analizzato le caratteristiche distintive della Reverse Logistics e in particolare delle reti che trattano i veicoli a fine vita. L’obiettivo finale dello studio è quello di elaborare e implementare, tramite l’utilizzo del software AMPL, un modello di ottimizzazione multi-obiettivo (MOP- Multi Objective Optimization) Lean e Green a una Reverse Supply Chain dei veicoli a fine vita. I risultati ottenuti evidenziano che è possibile raggiungere un ottimo compromesso tra le due logiche. E' stata effettuata anche una valutazione economica dei risultati ottenuti, che ha evidenziato come il trade-off scelto rappresenti anche uno degli scenari con minor costi.

Analisi ed efficientamento di un impianto tecnologico di lavorazione a freddo delle lamiere per la produzione di elettrodomestici in serie: il caso Electrolux S.p.A.

L'elaborato di tesi prende in esame il processo di produzione della linea “Pordenone”, in funzione nello stabilimento forlivese, di Electrolux S.P.A., azienda leader mondiale nella produzione di elettrodomestici e apparecchiature per l'uso domestico. Ragione del presente studio è l’acquisizione dell’opportuna comprensione del funzionamento dell’impianto al fine di individuare le inefficienze, le causali di fermata per la pianificazione della produzione o per gli interventi di manutenzione correttiva dei guasti, in modo da poter suggerire azioni di miglioramento. Per monitorare il processo di produzione è stato applicato all'oggetto di indagine lo studio del diagramma di Pareto, che ha permesso di evidenziare le principali causali all'origine della riduzione di produttività. Oltre a suggerire ipotesi di azioni di miglioramento, si è sottolineata l'importanza del coinvolgimento motivazionale degli operatori nelle procedure di lavoro, e l'opportunità di una maggiore implementazione del sistema informatico. Ragioni di carattere economico o di sicurezza dell'operatore, non hanno permesso di accogliere alcuni suggerimenti proposti, mentre sono state apportate migliorie nella produzione attraverso la riduzione delle fermate di lavoro. Nell'attuale clima di incertezza produttiva e di calo di domanda da parte di alcuni mercati, non è facile elaborare strategie di produzione innovative, tali da garantire la qualità del prodotto offerto e i risultati economici attesi, nel rispetto autentico dell'ambiente della collettività. Tuttavia, si ritiene che le informazioni generate da un adeguato monitoraggio del sistema offrano la possibilità di guardare avanti verso i progressi, piuttosto che concentrare la propria attenzione sulle opportunità mancate, e che le stesse informazioni possano trasformare l'agire dalla reattività (azione dopo il fatto) alla proattività (agire in anticipo) per migliorare efficacemente il processo di produzione.

[lean Production And Psychosocial Risks: The Case Of A Multinational Merger In A Metallurgical Company In Brazil].

This study focused on the method known as lean production as a work-related psychosocial risk factor in a Brazilian multinational auto parts company after its merger with other multinational companies. The authors conducted a qualitative analysis of two time points: the first using on-site observation and key interviews with managers and workers during implementation of lean production in 1996; the second, 16 years later, comparing data from a document search in labor inspection records from the Ministry of Labor and Employment and legal proceedings initiated by the Office of the Public Prosecutor for Labor Affairs. The merger led to layoffs, replacements, and an increase in the workday. A class action suit was filed on grounds of aggravated working conditions. The new production model led to psychosocial risks that increased the need for workers' health precautions when changes in the production process introduced new and increased risks of physical and mental illnesses.

Estimativa da probabilidade do evento extremo de precipitação de janeiro de 2000 no Vale do Paraíba, baseada na distribuição generalizada de pareto

Um evento extremo de precipitação ocorreu na primeira semana do ano 2000, de 1º a 5 de janeiro, no Vale do Paraíba, parte leste do Estado de São Paulo, Brasil, causando enorme impacto socioeconômico, com mortes e destruição. Este trabalho estudou este evento em 10 estações meteorológicas selecionadas que foram consideradas como aquelas tendo dados mais homogêneos do Que outras estações na região. O modelo de distribuição generalizada de Pareto (DGP) para valores extremos de precipitação de 5 dias foi desenvolvido, individualmente para cada uma dessas estações. Na modelagem da DGP, foi adotada abordagem não-estacionaria considerando o ciclo anual e tendência de longo prazo como co-variaveis. Uma conclusão desta investigação é que as quantidades de precipitação acumulada durante os 5 dias do evento estudado podem ser classificadas como extremamente raras para a região, com probabilidade de ocorrência menor do que 1% para maioria das estações, e menor do que 0,1% em três estações.

Evaluation of multifrequency bioelectrical impedance data for predicting lean tissue mass in beef cattle

Multifrequency bioimpedance analysis has the potential to provide a non-invasive technique for determining body composition in live cattle. A bioimpedance meter developed for use in clinical medicine was adapted and evaluated in 2 experiments using a total of 31 cattle. Prediction equations were obtained for total body water, extracellular body water, intracellular body water, carcass water and carcass protein. There were strong correlations between the results obtained through chemical markers and bioimpedance analysis when determined in cattle that had a wide range of liveweights and conditions. The r(2) values obtained were 0.87 and 0.91 for total body water and extracellular body water respectively. Bioimpedance also correlated with carcass water, measured by chemical analysis (r(2) = 0.72), but less well with carcass protein (r(2) = 0.46). These correlations were improved by inclusion of liveweight and sex as variables in multiple regression analysis. However, the resultant equations were poor predictors of protein and water content in the carcasses of a group of small underfed beef cattle, that had a narrow range of liveweights. In this case, although there was no statistical difference between the predicted and measured values overall, bioimpedance analysis did not detect the differences in carcass protein between the 2 groups that were apparent following chemical analysis. Further work is required to determine the sensitivity of the technique in small underfed cattle, and its potential use in heavier well fed cattle close to slaughter weight.

The pareto-stability concept is a natural solution concept for discrete matching markets with indifferences

In a decentralized setting the game-theoretical predictions are that only strong blockings are allowed to rupture the structure of a matching. This paper argues that, under indifferences, also weak blockings should be considered when these blockings come from the grand coalition. This solution concept requires stability plus Pareto optimality. A characterization of the set of Pareto-stable matchings for the roommate and the marriage models is provided in terms of individually rational matchings whose blocking pairs, if any, are formed with unmatched agents. These matchings always exist and give an economic intuition on how blocking can be done by non-trading agents, so that the transactions need not be undone as agents reach the set of stable matchings. Some properties of the Pareto-stable matchings shared by the Marriage and Roommate models are obtained.

Bone mineral apparent density in juvenile dermatomyositis: the role of lean body mass and glucocorticoid use

Objective: To analyse bone mineral density (BMD) in juvenile dermatomyositis (JDM) and its possible association with body composition, disease activity, duration of disease, glucocorticoid (GC) use, and biochemical bone parameters, including osteoprotegerin (OPG) and receptor activator of nuclear factor B (RANKL). Methods: Twenty girls with JDM and 20 controls matched for gender and age were selected. Body composition and BMD were analysed by dual-energy X-ray absorptiometry (DXA) and bone mineral apparent density (BMAD) was calculated. Duration of disease, cumulative GC, and GC pulse therapy use were determined from medical records. Disease activity and muscle strength were measured by the Disease Activity Score (DAS), the Childhood Myositis Assessment Scale (CMAS), and the Manual Muscle Test (MMT). Inflammatory and bone metabolism parameters were also analysed. OPG and RANKL were measured in patients and controls using an enzyme-linked immunosorbent assay (ELISA). Results: A lower BMAD in the femoral neck (p< 0.001), total femur (p< 0.001), and whole body (p=0.005) was observed in JDM patients compared to controls. Body composition analysis showed a lower lean mass in JDM compared to controls (p=0.015), but no difference was observed with regard to fat mass. A trend of lower serum calcium was observed in JDM (p=0.05), whereas all other parameters analysed, including OPG and RANKL, were similar. Multiple linear regression analysis revealed that, in JDM, lean mass (p< 0.01) and GC pulse therapy use (p< 0.05) were independent factors for BMAD in the hip region. Conclusions: This study has identified low lean mass and GC pulse therapy use as the major factors for low hip BMAD in JDM patients.

The influence of lean mass in trabecular and cortical bone in juvenile onset systemic lupus erythematosus

The aim of this study was to evaluate risk factors for low bone mineral density (BMD) and vertebral fractures, in juvenile systemic lupus (JSLE). Thirty-one consecutive patients with JSLE were compared with 31 gender- and age-matched healthy controls. BNID and body composition from all participants were measured using dual-energy X-ray absorptiometry. Vertebral fractures were defined as a reduction of >= 20% of the vertebral height for all patients. Lumbar spine and total femur BMD was significantly decreased in patients compared with controls (P = 0.021 and P = 0.023, respectively). A high frequency of vertebral fractures (22.58%) was found in patients with JSLE. Analysis of body composition revealed lower lean mass (P = 0.033) and higher fat mass percentage (P = 0.003) in patients than in controls. Interestingly, multiple linear regression using BMD as a dependent variable showed a significant association with lean mass in lumbar spine (R(2) = 0.262; P = 0.004) and total femur (R(2) = 0.419, P = 0.0001), whereas no association was observed with menarche age, SLE Disease Activity Index, Systemic Lupus International Collaborating Clinics/American College of Rheumatology, and glucocorticoid. This study indicates that low BMD and vertebral fractures are common in JSLE, and the former is associated with low lean mass, suggesting that muscle rehabilitation may be an additional target for bone therapeutic approach.

Indicators of lean body mass catabolism: emphasis on the creatinine excretion rate

Background: The major stress response to critical illness leads to a catabolic state and loss of lean body mass. Aims: To test whether an increased rate of creatinine excretion might provide unique and timely information to monitor cell catabolism; to relate this information to balances of cell constituents (nitrogen, potassium, phosphate and magnesium); to evaluate the effectiveness of nutritional therapy to reverse this catabolic process. Design: Prospective observational study. Methods: Children with severe traumatic brain injury admitted to the paediatric critical care units of The Hospital for Sick Children, Toronto, Canada and Hospital das Clnicas, Faculty of Medicine of Ribeiro Preto, University of So Paulo, Brazil were studied. Complete 24 h urine collections were obtained for measurement of creatinine excretion rate and daily balances of nitrogen, potassium, phosphate and magnesium. Results: Seventeen patients were studied for 310 days. On Day 1, all had negative balances for protein and phosphate. Balances for these intracellular constituents became positive when protein intake was >= 1 g/kg/day and energy intake was >= 50% of estimated energy expenditure (P < 0.0001). Creatinine excretion rate was positively correlated with the urea appearance rate (r = 0.60; P < 0.0001), and negatively with protein balance (r = -0.45; P < 0.0001). Sepsis developed in four patients; before its clinical detection, there were negative balances for all intracellular markers and an abrupt rise in the excretion of creatinine. Conclusions: Negative balances of intracellular components and an increase in rate of creatinine excretion heralded the onset of catabolism.

Conception of a flexible integrator and lean model for integrated management systems

Management systems standards (MSSs) have developed in an unprecedented manner in the last few years. These MSS cover a wide array of different disciplines, aims and activities of organisations. Also, organisations are populated with an enormous diversity of independent management systems (MSs). An integrated management system (IMS) tends to integrate some or all components of the business. Maximising their integration in one coherent and efficient MS is increasingly a strategic priority and constitutes an opportunity for businesses to be more competitive and consequently, promote its sustainable success. Those organisations that are quicker and more efficient in their integration and continuous improvement will have a competitive advantage in obtaining sustainable value in our global and competitive business world. Several scholars have proposed various theoretical approaches regarding the integration of management sub-systems, leading to the conclusion that there is no common practice for all organisations as they encompass different characteristics. One other author shows that several tangible and intangible gains for organisations, as well as to their internal and external stakeholders, are achieved with the integration of the individual standardised MSs. The purpose of this work was to conceive a model, Flexible, Integrator and Lean for IMSs, according to ISO 9001 for quality; ISO 14001 for environment and OHSAS 18001 for occupational health and safety (IMS–QES), that can be adapted and progressively assimilate other MSs, such as, SA 8000/ISO 26000 for social accountability, ISO 31000 for risk management and ISO/IEC 27001 for information security management, among others. The IMS–QES model was designed in the real environment of an industrial Portuguese small and medium enterprise, that over the years has been adopting, gradually, in whole or in part, individual MSSs. The developed model is based on a preliminary investigation conducted through a questionnaire. The strategy and research methods have taken into consideration the case study. Among the main findings of the survey we highlight: the creation of added value for the business through the elimination of several organisational wastes; the integrated management of the sustainability components; the elimination of conflicts between independent MS; dialogue with the main stakeholders and commitment to their ongoing satisfaction and increased contribution to the company’s competitiveness; and greater valorisation and motivation of employees as a result of the expansion of their skill base, actions and responsibilities, with their consequent empowerment. A set of key performance indicators (KPIs) constitute the support, in a perspective of business excellence, to the follow up of the organisation’s progress towards the vision and achievement of the defined objectives in the context of each component of the IMS model. The conceived model had many phases and the one presented in this work is the last required for the integration of quality, environment, safety and others individual standardised MSs. Globally, the investigation results, by themselves, justified and prioritised the conception of an IMS–QES model, to be implemented at the company where the investigation was conducted, but also a generic model of an IMS, which may be more flexible, integrator and lean as possible, potentiating the efficiency, added value both in the present and, fundamentally, for future.