Uma perspetiva Lean Seis Sigma na melhoria contínua de um sistema logístico de produção

A globalização da indústria leva a ambientes industriais cada vez mais competitivos em que a redução de desperdícios e melhoria dos sistemas produtivos e logísticos tornam-se fatores críticos para o sucesso e sustentabilidade de uma organização. Desta forma, a presente dissertação tem como âmbito a melhoria contínua em sistemas logísticos de produção através de uma perspetiva Lean Seis Sigma (modelo híbrido) testado e implementado na Visteon Portuguesa Lda. Neste modelo proposto serão identificadas oportunidades de melhoria no fluxo logístico de produção, no sistema de armazenamento e no processo produtivo e a sua implementação. Estas serão identificadas com base na elaboração do Value Stream Mapping (VSM) do processo produtivo do cluster B299 High. Posteriormente, serão aplicados métodos e ferramentas Lean e Seis Sigma que permitirão atingir o objetivo estipulado para cada uma. A nível do fluxo logístico de produção, foi introduzido o Systematic Layout Planning (SLP) de forma a estudar a configuração existente e as suas restrições, bem como a existência de um rearranjo na mesma que seja vantajoso para a redução do tempo despendido em transporte de materiais entre zonas da configuração. Com o intuito de minimizar o manuseamento dos materiais foi desenvolvido e proposto um novo sistema de transporte. Para a melhoria do sistema de armazenagem, foram criados armazéns distintos dependendo do tipo de material armazenado, e uma análise ABC para identificar quais os produtos com maior número de movimentações e assim, definir qual a melhor configuração das localizações nas racks. Para o abastecimento dos materiais, torna-se também necessário a conceção e implementação de um sistema order picking, tendo como objetivo a agilização do sistema de armazenagem. Por último, foi desenvolvido um estudo DMAIC para melhorar o processo produtivo, com o intuito de aumentar a performance do mesmo através da redução de scrap.

Aplicação da metodologia lean seis sigma na otimização do nível de stocks: caso de estudo na indústria vidreira

Com a crescente competitividade dos mercados, em parte devido à conjuntura económica atual, as organizações viram-se obrigadas a adotar estratégias de gestão que lhes permitissem reduzir custos e aumentar a eficácia e eficiência dos seus processos. Como tal, são cada vez mais as empresas que apostam em práticas de melhoria contínua, para de um modo estruturado fazerem face ao desperdício gerado ao longo da cadeia de abastecimento, bem como à variabilidade dos seus processos. Uma das abordagens frequentemente utilizada dentro das empresas industriais é o Lean Seis Sigma. O ciclo DMAIC é um método sequencial que por meio das etapas Define, Measure, Analyse, Improve e Control, auxilia a implementação estruturada de iniciativas de melhoria contínua, tais como os projetos Lean Seis Sigma. O objetivo do caso de estudo da presente dissertação é, através da criação de stocks de segurança e da otimização do nível de stocks de produto acabado, alcançar uma redução do valor financeiro imobilizado no armazém de produto final de uma empresa da indústria vidreira. Nesse sentido, foram aplicadas diversas ferramentas Lean e Seis Sigma com o intuito de recolher dados válidos, analisar as causas da raiz do problema e ulteriormente propor as devidas melhorias. Constatou-se que a inexistência de stocks de segurança, bem como a ausência de uma classificação dos stocks de acordo a média diária de expedições, influi negativamente na organização dos níveis de stock de uma empresa, levando a que a rotatividade dos artigos seja reduzida. Consequentemente, a aplicação do ciclo DMAIC, com especial enfoque na Análise ABC como ferramenta de gestão e controlo de stocks, gera benefícios que podem ser traduzidos para outras organizações, ao nível do aumento da qualidade e da satisfação dos clientes.

Aplicação do Seis Sigma na avaliação da inexatidão dos resultados laboratoriais do parâmetro cortisol sérico

No desenvolvimento deste caso de estudo, dentro do Programa Nacional de Avaliação Externa da Qualidade do Instituto Nacional de Saúde Doutor Ricardo Jorge utilizou-se o Seis Sigma como metodologia e como métrica, de maneira a estruturar de forma intuitiva a sua aplicação na resolução de problemas e definir o principal objetivo. Como metodologia, o Seis Sigma recorre a diversas técnicas e ferramentas da qualidade, que visam a melhoria contínua de procedimentos. Enquanto métrica, o Seis Sigma apresenta uma meta a atingir para a qualidade. O ideal seria atingir-se a meta dos Seis Sigma, que significa 3,4 defeitos por milhão de oportunidades (taxa de defeitos de um determinado procedimento). Para reduzir a variabilidade de resultados entre laboratórios, referentes ao parâmetro Cortisol Sérico, aplicou-se o ciclo DMAIC (Define – Measure – Analyze – Improve – Control), a que correspondem cinco etapas diferentes. Em cada uma destas etapas utilizam-se as técnicas e ferramentas da qualidade, como referido anteriormente acerca do Seis Sigma enquanto metodologia, com o objetivo de melhorar processos. Inicia-se a primeira etapa com a identificação do problema e finaliza-se a última com o controlo e monitorização dos efeitos provocados pelas ações de melhoria implementadas. O objetivo dos programas de Avaliação Externa da Qualidade do Programa Nacional de Avaliação Externa da Qualidade é avaliar a performance quanto à variabilidade/uniformidade de resultados entre os laboratórios participantes. É de extrema importância a harmonização de resultados clínicos entre laboratórios, pois são estes resultados que fornecem informações ao profissional de saúde, sobre o estado de saúde do paciente, auxiliando no diagnóstico, tratamento e controlo de doenças. Caso isto não aconteça, será um fator crítico que pode fazer a diferença na saúde pública. Foram identificadas as causas de erros sistemáticos, causas de inexatidão laboratorial, a nível de métodos, equipamentos, reagentes e calibradores utilizados em laboratório e implementadas ações de melhoria mais relevantes. No final obteve-se um nível de qualidade sigma superior ao inicial, tal como tinha sido previsto nos objetivos. O nível da qualidade deve ser controlado ao longo do tempo, com o objetivo de identificar novas anomalias e melhorar continuamente.

Implementation of a lean six sigma project in a production line

Companies from the motorcycles components branch are dealing with a dynamic environment, resulting from the introduction of new products and the increase of market demand. This dynamic environment requires frequent changes in production lines and requires flexibility in the processes, which can cause reductions in the level of quality and productivity. This paper presents a Lean Six Sigma improvement project performed in a production line of the company's machining sector, in order to eliminate losses that cause low productivity, affecting the fulfillment of the production plan and customer satisfaction. The use of Lean methodology following the DMAIC stages allowed analyzing the factors that influence the line productivity loss. The major problems and causes that contribute to a reduction on productivity and that were identified in this study are the lack of standardization in the setup activities and the excessive stoppages for adjustment of the processes that caused an increase of defects. Control charts, Pareto analysis and cause-and-effect diagrams were used to analyze the problem. On the improvement stage, the changes were based on the reconfiguration of the line layout as well as the modernization of the process. Overall, the project justified an investment in new equipment, the defective product units were reduced by 84% and an increase of 29% of line capacity was noticed.

Redução de contaminações: um projeto de melhoria contínua em ambiente seis sigma

Dissertação de mestrado integrado em Engenharia e Gestão Industrial

Amplification of the housekeeping sigma factor in Pseudomonas fluorescens CHA0 enhances antibiotic production and improves biocontrol abilities.

Pseudomonas fluorescens CHA0 produces a variety of secondary metabolites, in particular the antibiotics pyoluteorin and 2,4-diacetylphloroglucinol, and protects various plants from diseases caused by soilborne pathogenic fungi. The rpoD gene encoding the housekeeping sigma factor sigma 70 of P. fluorescens was sequenced. The deduced RpoD protein showed 83% identity with RpoD of Pseudomonas aeruginosa and 67% identity with RpoD of Escherichia coli. Attempts to inactivate the single chromosomal rpoD gene of strain CHA0 were unsuccessful, indicating an essential role of this gene. When rpoD was carried by an IncP vector in strain CHA0, the production of both antibiotics was increased severalfold and, in parallel, protection of cucumber against disease caused by Pythium ultimum was improved, in comparison with strain CHA0.

Role of the stress sigma factor RpoS in GacA/RsmA-controlled secondary metabolism and resistance to oxidative stress in Pseudomonas fluorescens CHA0.

In Pseudomonas fluorescens biocontrol strain CHA0, the two-component system GacS/GacA positively controls the synthesis of extracellular products such as hydrogen cyanide, protease, and 2,4-diacetylphloroglucinol, by upregulating the transcription of small regulatory RNAs which relieve RsmA-mediated translational repression of target genes. The expression of the stress sigma factor sigmaS (RpoS) was controlled positively by GacA and negatively by RsmA. By comparison with the wild-type CHA0, both a gacS and an rpoS null mutant were more sensitive to H2O2 in stationary phase. Overexpression of rpoS or of rsmZ, encoding a small RNA antagonistic to RsmA, restored peroxide resistance to a gacS mutant. By contrast, the rpoS mutant showed a slight increase in the expression of the hcnA (HCN synthase subunit) gene and of the aprA (major exoprotease) gene, whereas overexpression of sigmaS strongly reduced the expression of these genes. These results suggest that in strain CHA0, regulation of exoproduct synthesis does not involve sigmaS as an intermediate in the Gac/Rsm signal transduction pathway whereas sigmaS participates in Gac/Rsm-mediated resistance to oxidative stress.

In Bacillus subtilis W23, the duet sigmaXsigmaM, two sigma factors of the extracytoplasmic function subfamily, are required for septum and wall synthesis under batch culture conditions.

The synthesis of poly(RboP), the main Bacillus subtilis W23 teichoic acid, is encoded by tarDF-tarABIJKL operons, the latter being controlled by two promoters designated PtarA-int and PtarA-ext. Analysis by lacZ fusions reveals that PtarA-int activity exhibits sharp increases at the beginning and end of the transition between exponential and stationary growth phase. As confirmed by mRNA quantification, these increases are mediated by ECF sigma factors sigmaX and sigmaM respectively. In liquid media, strain W23 sigX sigM double mutants experience serious difficulties in the transition and stationary growth phases. Inactivation of sigmaX- and sigmaM-controlled regulons, which precludes transcription from PtarA-int, leads to (i) delays in chromosome segregation and septation and (ii) a transient loss of up to 30% of the culture OD or lysis. However, specific inactivation of PtarA-int, leading mainly to a shortage of poly(RboP), does not affect growth while, nevertheless, interfering with normal septation, as revealed by electron microscopy. The different sigM transcription in strains W23 and 168 is discussed. In W23, expression of tarA and sigM, which is shown to control divIC, is inversely correlated with growth rate, suggesting that the sigM regulon is involved in the control of cell division.

Analysis of teichoic acid biosynthesis regulation reveals that the extracytoplasmic function sigma factor sigmaM is induced by phosphate depletion in Bacillus subtilis W23.

The expression of the Bacillus subtilis W23 tar genes specifying the biosynthesis of the major wall teichoic acid, the poly(ribitol phosphate), was studied under phosphate limitation using lacZ reporter fusions. Three different regulation patterns can be deduced from these beta-galactosidase activity data: (i) tarD and tarL gene expression is downregulated under phosphate starvation; (ii) tarA and, to a minor extent, tarB expression after an initial decrease unexpectedly increases; and (iii) tarO is not influenced by phosphate concentration. To dissect the tarA regulatory pattern, its two promoters were analysed under phosphate limitation: The P(tarA)-ext promoter is repressed under phosphate starvation by the PhoPR two-component system, whereas, under the same conditions, the P(tarA)-int promoter is upregulated by the action of an extracytoplasmic function (ECF) sigma factor, sigma(M). In contrast to strain 168, sigma(M) is activated in strain W23 in phosphate-depleted conditions, a phenomenon indirectly dependent on PhoPR, the two-component regulatory system responsible for the adaptation to phosphate starvation. These results provide further evidence for the role of sigma(M) in cell-wall stress response, and suggest that impairment of cell-wall structure is the signal activating this ECF sigma factor.

Hypermethylated 14-3-3-sigma and ESR1 gene promoters in serum as candidate biomarkers for the diagnosis and treatment efficacy of breast cancer metastasis

Background: Numerous hypermethylated genes have been reported in breast cancer, and the silencing of these genes plays an important role in carcinogenesis, tumor progression and diagnosis. These hypermethylated promoters are very rarely found in normal breast. It has been suggested that aberrant hypermethylation may be useful as a biomarker, with implications for breast cancer etiology, diagnosis, and management. The relationship between primary neoplasm and metastasis remains largely unknown. There has been no comprehensive comparative study on the clinical usefulness of tumor-associated methylated DNA biomarkers in primary breast carcinoma and metastatic breast carcinoma. The objective of the present study was to investigate the association between clinical extension of breast cancer and methylation status of Estrogen Receptor1 (ESR1) and Stratifin (14-3-3-σ) gene promoters in disease-free and metastatic breast cancer patients. Methods: We studied two cohorts of patients: 77 patients treated for breast cancer with no signs of disease, and 34 patients with metastatic breast cancer. DNA was obtained from serum samples, and promoter methylation status was determined by using DNA bisulfite modification and quantitative methylation-specific PCR. Results: Serum levels of methylated gene promoter 14-3-3-σ significantly differed between Control and Metastatic Breast Cancer groups (P < 0.001), and between Disease-Free and Metastatic Breast Cancer groups (P < 0.001). The ratio of the 14-3-3-σ level before the first chemotherapy cycle to the level just before administration of the second chemotherapy cycle was defined as the Biomarker Response Ratio [BRR]. We calculated BRR values for the "continuous decline" and "rise-and-fall" groups. Subsequent ROC analysis showed a sensitivity of 75% (95% CI: 47.6 - 86.7) and a specificity of 66.7% (95% CI: 41.0 - 86.7) to discriminate between the groups for a cut-off level of BRR = 2.39. The area under the ROC curve (Z = 0.804 ± 0.074) indicates that this test is a good approach to post-treatment prognosis. Conclusions: The relationship of 14-3-3-σ with breast cancer metastasis and progression found in this study suggests a possible application of 14-3-3-σ as a biomarker to screen for metastasis and to follow up patients treated for metastatic breast cancer, monitoring their disease status and treatment response.

The sigma factor AlgU (AlgT) controls exopolysaccharide production and tolerance towards desiccation and osmotic stress in the biocontrol agent Pseudomonas fluorescens CHA0.

A variety of stress situations may affect the activity and survival of plant-beneficial pseudomonads added to soil to control root diseases. This study focused on the roles of the sigma factor AlgU (synonyms, AlgT, RpoE, and sigma(22)) and the anti-sigma factor MucA in stress adaptation of the biocontrol agent Pseudomonas fluorescens CHA0. The algU-mucA-mucB gene cluster of strain CHA0 was similar to that of the pathogens Pseudomonas aeruginosa and Pseudomonas syringae. Strain CHA0 is naturally nonmucoid, whereas a mucA deletion mutant or algU-overexpressing strains were highly mucoid due to exopolysaccharide overproduction. Mucoidy strictly depended on the global regulator GacA. An algU deletion mutant was significantly more sensitive to osmotic stress than the wild-type CHA0 strain and the mucA mutant were. Expression of an algU'-'lacZ reporter fusion was induced severalfold in the wild type and in the mucA mutant upon exposure to osmotic stress, whereas a lower, noninducible level of expression was observed in the algU mutant. Overexpression of algU did not enhance tolerance towards osmotic stress. AlgU was found to be essential for tolerance of P. fluorescens towards desiccation stress in a sterile vermiculite-sand mixture and in a natural sandy loam soil. The size of the population of the algU mutant declined much more rapidly than the size of the wild-type population at soil water contents below 5%. In contrast to its role in pathogenic pseudomonads, AlgU did not contribute to tolerance of P. fluorescens towards oxidative and heat stress. In conclusion, AlgU is a crucial determinant in the adaptation of P. fluorescens to dry conditions and hyperosmolarity, two major stress factors that limit bacterial survival in the environment.