Utilização de simulação a eventos discretos como ferramenta gerencial para auxiliar no planejamento de produção em uma fundição de grande porte
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Data
2023-03-24
Autores
Turner, Breno Zeraik Lima
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Editor
Universidade Estadual Paulista (Unesp)
Resumo
Em um contexto de crescente competitividade, o Planejamento e Controle de Produção vem desempenhando papel fundamental nas corporações e tem sido visto como elemento crítico para o sucesso de qualquer organização. Sobretudo em uma fundição, a tarefa de programar a produção é bastante complexa, dadas as características peculiares de seus processos. Enquanto a fabricação de aço corresponde a um processo em batelada, a produção de moldes opera em um fluxo contínuo. Deste modo, o Planejamento e Controle de Produção, numa fundição, tem o desafio de garantir o sincronismo dessas duas atividades, distintas entre si, mas que operam de forma simultânea. Apesar de existirem trabalhos relacionados à programação de produção em fundições, não foram identificadas, na revisão de literatura, pesquisas que abordaram a utilização de Simulação a Eventos Discretos para auxiliar no planejamento de produção. Nesse sentido, este trabalho mostrou-se inovador ao utilizar Simulação a Eventos Discretos para desenvolver uma ferramenta gerencial, com o objetivo de propor soluções viáveis para diminuir o Work in Progress nos pátios de vazamento, de modo a impedir a ocorrência de bloqueios nas linhas de moldagem. Adotou-se a técnica IDEF-SIM para a modelagem conceitual e um software comercial para construção do modelo computacional. O modelo foi validado estatisticamente por meio de uma técnica para dados normais, e a ferramenta desenvolvida provou-se apropriada para responder questões de planejamento de níveis operacional, tático e estratégico. Diferentes cenários foram experimentados e as respostas das simulações auxiliaram a gerência da empresa em processos de tomada de decisão, de determinação de escalas de trabalho a definição de investimentos em modernização de equipamentos.
Under the increasing competitiveness environment, Production Planning and Control has been playing a key role in corporations and has been seen as a critical element for the success of any organization. Especially in a foundry, the task of scheduling is quite complex, given the specific characteristics of its processes. While melting is a batch process, moldmaking is a one-piece flow system. Hence, Production Planning and Control in a foundry has the challenge of guaranteeing the synchronism between these two processes, which are distinct, but operate simultaneously. Although there are researches related to production planning in foundries, studies which addressed the use of Discrete Event Simulation to assist in the production planning task have not been identified. Thus, this piece of research has been proved to be innovative by using Discrete Event Simulation to develop a management tool whose objective is to propose viable solutions to reduce the Work in Progress in the pouring floor in order to prevent the occurrence of blockage in the molding lines. The IDEF-SIM technique has been adopted to develop the conceptual modeling and a commercial software has been used to build the computational model. The model has been statistically validated by means of a technique for normal distributions and the developed tool has been demonstrated to be useful to answer production planning questions at operational, tactical, and strategic levels. Different scenarios have been experimented and the outputs have supported the company management in decision- making processes, from determining work shifts to defining investments in equipment modernization.
Under the increasing competitiveness environment, Production Planning and Control has been playing a key role in corporations and has been seen as a critical element for the success of any organization. Especially in a foundry, the task of scheduling is quite complex, given the specific characteristics of its processes. While melting is a batch process, moldmaking is a one-piece flow system. Hence, Production Planning and Control in a foundry has the challenge of guaranteeing the synchronism between these two processes, which are distinct, but operate simultaneously. Although there are researches related to production planning in foundries, studies which addressed the use of Discrete Event Simulation to assist in the production planning task have not been identified. Thus, this piece of research has been proved to be innovative by using Discrete Event Simulation to develop a management tool whose objective is to propose viable solutions to reduce the Work in Progress in the pouring floor in order to prevent the occurrence of blockage in the molding lines. The IDEF-SIM technique has been adopted to develop the conceptual modeling and a commercial software has been used to build the computational model. The model has been statistically validated by means of a technique for normal distributions and the developed tool has been demonstrated to be useful to answer production planning questions at operational, tactical, and strategic levels. Different scenarios have been experimented and the outputs have supported the company management in decision- making processes, from determining work shifts to defining investments in equipment modernization.
Descrição
Palavras-chave
planejamento e controle de produção, simulação a eventos discretos, IDEF-SIM, foundry, production planning and control, discrete event simulation, Planejamento da produção, Fundição, Métodos de simulação