Ferramenta A3 aplicada na redução do tempo de fabricação de um rolamento de giro de grande porte
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Data
2020-07-29
Autores
Polizel, Murilo Henrique
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Editor
Universidade Estadual Paulista (Unesp)
Resumo
Num mercado altamente competitivo, no qual os preços dos produtos são fixos e o cliente está
cada vez mais exigente, o método de trabalho sustentado pela produção em massa não é mais
viável, portanto é preciso adotar novas filosofias que objetivem levar o desempenho dos
processos a um patamar superior. A produção enxuta ou lean, derivada do Sistema Toyota de
Produção, por meio de conceitos, metodologias e ferramentas os quais colocam os valores do
cliente como prioridade número um, é a saída para que as empresas alcancem a
competitividade necessária para sustentarem-se e destacarem-se no mercado. Com base nas
ferramentas de análise e soluções de problemas utilizadas no lean, este trabalho tem como
objetivo a aplicação da ferramenta A3 na redução do tempo de fabricação de um rolamento de
giro de grande porte, e apresenta todos os conceitos e metodologias envolvidos para ser usado
como referência na análise e soluções de quaisquer outros problemas enfrentados. A aplicação
da ferramenta teve um resultado satisfatório no problema enfrentado, já que o tempo de
fabricação do rolamento estava 105% fora da meta, e ao final do projeto ficou apenas 10%
fora da meta, totalizando uma redução de 7 horas no tempo de fabricação. Além do resultado
técnico, os impactos do projeto foram intangíveis na linha de negócio da empresa, pois os
tempos de fabricação de todos os outros rolamentos também foram reduzidos, devido à
difusão da cultura de melhoria contínua entre todos os colaboradores
In a highly competitive market, in which product prices are fixed and the customer is increasingly demanding, the method of work supported by mass production is no longer viable, so it is necessary to adopt new philosophies that aim to take the performance of processes to a higher level. Lean or lean production, derived from the Toyota Production System, through concepts, methodologies and tools that place the customer's values as number one priority, is the way for companies to achieve the necessary competitiveness to sustain themselves and stand out on the market. Based on analysis and solutions problem tools used in lean, this work aims to apply the A3 tool in reducing the manufacturing time of a large slewing bearing, and presents all the concepts and methodologies involved to be used as a reference in the analysis and solutions of any other problems faced. The application of the tool had a satisfactory result in the problem faced, since the time of manufacture of the bearing was 105% outside the target, and at the end of the project it was only 10% outside the target, totaling a reduction of 7 hours in the manufacturing time. In addition to the technical result, the project's impacts were intangible in the company's business line, as the manufacturing times for all other bearings were also reduced, due to the dissemination of the culture of continuous improvement among all employees
In a highly competitive market, in which product prices are fixed and the customer is increasingly demanding, the method of work supported by mass production is no longer viable, so it is necessary to adopt new philosophies that aim to take the performance of processes to a higher level. Lean or lean production, derived from the Toyota Production System, through concepts, methodologies and tools that place the customer's values as number one priority, is the way for companies to achieve the necessary competitiveness to sustain themselves and stand out on the market. Based on analysis and solutions problem tools used in lean, this work aims to apply the A3 tool in reducing the manufacturing time of a large slewing bearing, and presents all the concepts and methodologies involved to be used as a reference in the analysis and solutions of any other problems faced. The application of the tool had a satisfactory result in the problem faced, since the time of manufacture of the bearing was 105% outside the target, and at the end of the project it was only 10% outside the target, totaling a reduction of 7 hours in the manufacturing time. In addition to the technical result, the project's impacts were intangible in the company's business line, as the manufacturing times for all other bearings were also reduced, due to the dissemination of the culture of continuous improvement among all employees
Descrição
Palavras-chave
Sistema Toyota de produção (TPS), Produção enxuta, Ferramenta A3, Análise e solução de problemas, Toyota production system (TPS), Lean production, Lean, A3 tool, Problem analysis and solutions, Processo decisório, Lean manufacturing