A produção enxuta em um sistema de fabricação contínuo: aplicação da simulação discreta estocástica na indústria de condutores elétricos
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Data
2012-12-13
Autores
Lourenço Junior, José [UNESP]
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Editor
Universidade Estadual Paulista (Unesp)
Resumo
É expressiva a repercussão do conceito da Produção Enxuta e grande parte das histórias de sucesso vem da indústria automotiva e de outras de fabricação de produtos discretos. Estas se caracterizam por volumes elevados e uma variedade relativamente pequena de produtos. Entretanto, constatou-se na literatura a carência de abordagens que tratem da Produção Enxuta aplicada à manufatura contínua onde os equipamentos de produção são, não raro, grandes, de elevado custo e relativamente fixos. Os processos contínuos de fabricação são menos flexíveis e não se adequam, por exemplo, a um arranjo celular como os da manufatura discreta. Neste contexto, o objetivo do presente trabalho é o de investigar a aplicabilidade do conceito da Produção Enxuta e de suas ferramentas à indústria de manufatura contínua, em particular na fabricação de condutores elétricos. Acerca da metodologia desta pesquisa, de início, um survey exploratório com fabricantes paulistas de condutores elétricos é realizado. Em seguida, a partir de dados ex-post facto de um fabricante com extenso histórico de prática dos conceitos da Produção Enxuta, foi realizado o mapeamento do fluxo de valor (VSM). Idealizou-se então o mapa do estado futuro considerado as condições de contorno e/ou adaptação das práticas enxutas a serem adotadas e seus os impactos são investigados por meio de simulação discreta estocástica. Os resultados obtidos do survey permitem inferir que o conceito ainda requer uma evolução mais significativa, naquele universo pesquisado. Já os resultados da simulação, avaliados por meio de um planejamento de experimentos e a avaliação simultânea das variáveis de saída, pelo Método Plackett-Burman, apontam a significativos ganhos, por exemplo, reduções de lead-time e estoque em processo. Em conclusão, foi...
It is significant the repercussion of the concept of Lean Production, much of the success cases come from the automotive industry and other manufacturing discrete products. Those industries are characterized by high volumes and a relatively small assortment of products. However, there was a lack of literature on approaches those address Lean Production applied to continuous manufacturing where production equipment are, not rarely, large, high cost and relatively fixed. The continuous manufacturing is less flexible and not suitable, for example, a cellular layout as discrete manufacturing. In this context, the objective of this thesis is to investigate the applicability of the concept of Lean Production and its tools for continuous manufacturing industry, particularly in the manufacture of electrical conductors. About the methodology of this research, at first, an exploratory survey with manufacturers of electrical conductors is performed. Then, data from ex-post facto from a manufacturer with long history of practice of the concepts of Lean Production was held VSM - Value Stream Mapping. After was envisioned future state map considered the boundary conditions and/or adaptation of lean practices to be adopted and their impacts are investigated by means of discrete stochastic simulation. The results of the survey allow us to infer that the concept still requires a more significant development in that universe surveyed. Already the simulation results, evaluated by means of a design of experiments and the simultaneous evaluation of the output variables, by the use of the Plackett-Burman Method, point to significant gains, for example, in reducing the lead time and the amount of stock in process. In conclusion, it was demonstrated for the industrial environment studied, continuous manufacturing eminently, the possibility... (Complete abstract click electronic access below)
It is significant the repercussion of the concept of Lean Production, much of the success cases come from the automotive industry and other manufacturing discrete products. Those industries are characterized by high volumes and a relatively small assortment of products. However, there was a lack of literature on approaches those address Lean Production applied to continuous manufacturing where production equipment are, not rarely, large, high cost and relatively fixed. The continuous manufacturing is less flexible and not suitable, for example, a cellular layout as discrete manufacturing. In this context, the objective of this thesis is to investigate the applicability of the concept of Lean Production and its tools for continuous manufacturing industry, particularly in the manufacture of electrical conductors. About the methodology of this research, at first, an exploratory survey with manufacturers of electrical conductors is performed. Then, data from ex-post facto from a manufacturer with long history of practice of the concepts of Lean Production was held VSM - Value Stream Mapping. After was envisioned future state map considered the boundary conditions and/or adaptation of lean practices to be adopted and their impacts are investigated by means of discrete stochastic simulation. The results of the survey allow us to infer that the concept still requires a more significant development in that universe surveyed. Already the simulation results, evaluated by means of a design of experiments and the simultaneous evaluation of the output variables, by the use of the Plackett-Burman Method, point to significant gains, for example, in reducing the lead time and the amount of stock in process. In conclusion, it was demonstrated for the industrial environment studied, continuous manufacturing eminently, the possibility... (Complete abstract click electronic access below)
Descrição
Palavras-chave
Condutores eletricos, Administração da produção, Lean manufacturing
Como citar
LOURENÇO JUNIOR, José. A produção enxuta em um sistema de fabricação contínuo: aplicação da simulação discreta estocástica na indústria de condutores elétricos. 2012. 133 f. Tese (doutorado) – Universidade Estadual Paulista, Faculdade de Engenharia de Guaratinguetá, 2012.