Utilização da simulação a eventos discretos para o gerenciamento do almoxarifado de materiais utilizados numa indústria automotiva
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Data
2018-09-27
Autores
Santana, Wagner Augusto Lemos de
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Universidade Estadual Paulista (Unesp)
Resumo
Os processos de recebimento, conferência, armazenagem, separação de pedidos, montagem de kits, distribuição de materiais e inventário são processos vitais dentro dos almoxarifados e interferem diretamente na efetividade da Cadeia de Suprimentos (Supply Chain - SC). Como esses processos sofrem várias interferências, devido a outros processos da SC, como compra de materiais, planejamento, programação e abastecimento da produção, tornam-se comuns situações como excessos de materiais, baixa acuracidade dos estoques, dificuldade de localização, falhas no atendimento dos pedidos e montagem de kits, entre outros. Pensando nestas dificuldades gerenciais, busca-se, nesta dissertação, utilizar uma pesquisa de natureza aplicada, com objetivos empíricos e descritivos e análise quantitativa para desenvolver uma ferramenta gerencial, com base em um modelo de simulação a eventos discretos, como apoio às decisões sobre os recursos necessários para execução de forma efetiva dos processos citados. O objeto de estudo foi um almoxarifado de produtos estampados de uma empresa multinacional no setor automotivo. Onde a criação de um modelo conceitual e aplicação da simulação foram os objetivos. Adotou-se a técnica IDEF-SIM para a modelagem conceitual do problema e foi utilizado o software ProModel® para se obter uma racionalização na aplicação dos recursos necessários para que o almoxarifado tenha um melhor desempenho, frente a vários cenários possíveis de ocorrer. Identificou-se, após a simulação, que um dos problemas principais na operação do almoxarifado estava relacionado com a chegada desbalanceada dos itens que formam os kits, outro dizia respeito ao tempo excessivo envolvido no processo de desengraxe dos componentes e kits montados, além da falta de racks para armazenagem dos kits, distribuição das equipes e turnos de trabalho. Como resposta aos problemas foram aplicadas melhorias nas embalagens, equipamento de desengraxe e redistribuição da equipe com redução de turno.
The processes of receiving, conferring, storing, sorting orders, assembling kits, distributing materials and inventory are vital processes within warehouses and directly interfere with the effectiveness of the Supply Chain (SC). As these processes suffer several interferences, due to other SC processes, such as material purchase, planning, scheduling and production supply, situations such as material excesses, low inventory accuracy, difficulty in locating, ordering and assembling kits, among others. In this dissertation, we intend to use a research of an applied nature, with empirical and descriptive objectives and quantitative analysis to develop a managerial tool, based on a simulation model to discrete events, as support to the decisions about the necessary resources to effectively execute the cited cases. The object of study was a warehouse of stamped products of a multinational company in the automotive sector. Where the creation of a conceptual model and application of the simulation were the objectives. The IDEF-SIM technique was adopted for the conceptual modeling of the problem and ProModel® software was used to obtain a rationalization in the application of the necessary resources so that the warehouse performs better, against several possible scenarios to occur. It was found after the simulation that one of the main problems in the operation of the warehouse was related to the unbalanced arrival of the items that form the kits, another one related to the excessive time involved in the degreasing process of the components and kits assembled, besides the lack of racks for storage of kits, distribution of teams and work shifts. In response to the problems were applied improvements in the packaging, degreasing equipment and redistribution of the team with reduction of shift.
The processes of receiving, conferring, storing, sorting orders, assembling kits, distributing materials and inventory are vital processes within warehouses and directly interfere with the effectiveness of the Supply Chain (SC). As these processes suffer several interferences, due to other SC processes, such as material purchase, planning, scheduling and production supply, situations such as material excesses, low inventory accuracy, difficulty in locating, ordering and assembling kits, among others. In this dissertation, we intend to use a research of an applied nature, with empirical and descriptive objectives and quantitative analysis to develop a managerial tool, based on a simulation model to discrete events, as support to the decisions about the necessary resources to effectively execute the cited cases. The object of study was a warehouse of stamped products of a multinational company in the automotive sector. Where the creation of a conceptual model and application of the simulation were the objectives. The IDEF-SIM technique was adopted for the conceptual modeling of the problem and ProModel® software was used to obtain a rationalization in the application of the necessary resources so that the warehouse performs better, against several possible scenarios to occur. It was found after the simulation that one of the main problems in the operation of the warehouse was related to the unbalanced arrival of the items that form the kits, another one related to the excessive time involved in the degreasing process of the components and kits assembled, besides the lack of racks for storage of kits, distribution of teams and work shifts. In response to the problems were applied improvements in the packaging, degreasing equipment and redistribution of the team with reduction of shift.
Descrição
Palavras-chave
Almoxarifado enxuto., Simulação a eventos discretos., Modelagem com IDEF-SIM., Montagem de kits., Indústria automobilística – Controle de estoque, Administração de material, Almoxarifados, Logística empresarial, Lean warehousing, Discrete event simulation, Modeling with IDEF-SIM, Kits assembly