Rápida resposta para produção (2RP) : uma proposta de integração entre ferramentas da qualidade voltadas ao mapeamento das falhas em produtos no pós-venda

Orientador : Prof. Dr. Fabiano Oscar DrozdaDissertação (mestrado) - Universidade Federal do Paraná, Setor de Tecnologia, Programa de Pós-Graduação em Engenharia de Produção. Defesa: Curitiba, 22/02/2017Inclui referências : f. 113-118Resumo: A presente dissertação visa contribuir para a área de diagnóstico de falhas em produtos de fabricação em massa após terem sido vendidos ao consumidor final. Para alcançar este objetivo, foi proposta a metodologia 2RP (Rapid Response For Production), a qual integra as seguintes ferramentas: Diagrama de Pareto, Diagrama de Afinidades, Diagrama FAST e Diagrama Matriz, sendo esta última auxiliada pela lógica difusa, a fim de superar as limitações ao pontuar as variáveis correlacionadas. Para validar a metodologia, foi feita uma aplicação em um caso prático, utilizando a base de dados da empresa Alpha, extraídas da plataforma virtual Reclame Aqui. Na primeira etapa, a metodologia serviu para identificar o produto e suas principais reclamações por meio do uso das ferramentas Diagramas de Pareto e Diagrama de Afinidade. Na segunda etapa, o produto foi caracterizado e classificado em suas funções básicas e secundárias, mediante o Diagrama FAST. Já na terceira etapa, utilizou-se o Diagrama Matriz para relacionar os principais problemas com os componentes que afetam o desempenho do produto para, assim, identificar os componentes que causaram a falha. Finalmente, o resultado obtido após a aplicação da metodologia 2RP permite que as empresas possam tomar ações para corrigir problemas de produção a fim de evitar reincidências de falhas e, consequentemente, de reclamações. Palavras-chave: Diagnóstico de Falhas, Metodologia híbrida, Técnicas de Qualidade, Lógica Difusa. Áreas de conhecimento: Engenharia de Produção; Engenharia da QualidadeAbstract: The following master thesis aims to contribute to the area of diagnosis of failures in mass-produced products after being sold to the final consumer. To reach this objective, the Rapid Response For Production (2RP) methodology was proposed, which integrates the following tools: Pareto Diagram, Affinity Diagram, FAST Diagram and Matrix Diagram, this last tool being aided by diffuse logic to overcome the limitations when punctuating the correlated variables. Methodology validation was applied in a practical case, using the Alpha company database, extracted from the virtual platform Reclame Aqui. In the first step, the methodology served to identify the product and its main complaints through the use of the Pareto Diagrams and Affinity Diagram tools. In the second step, the product was characterized and classified in its essential and secondary functions, through the FAST Diagram. In the third step, the Matrix Diagram was used to relate the main problems with the components that affect the performance of the product to identify which ones caused the failure. Finally, the result obtained after applying the 2RP methodology allows companies to take actions to correct production problems to avoid recurrence of failures and, consequently, complaints. Keywords: Fault Diagnosis, Hybrid Methodology, Quality Techniques, Fuzzy Logic. Areas of expertise: Production Engineering; Quality Engineeri

Uses of Lean Manufacturing tools to improve the efficiency of production flow in a can factory

This work was developed in a company that produces metallic cans and that does not adopt the philosophy of Lean Manufacturing. The need to provide products with different characteristics turned out the production process to be complex, inefficient, and large stock between operations. The goal was to improve the productivity by identifying and eliminating waste. The starting point was the elaboration of the VSM of current status to identify potential improvement. The VSM (Value Stream Map) analysis showed that the pieces of equipment and the lithographic machine have OEE (Overall Equipment Effectiveness) at a quite low rate, around 26,95%, which led the need for additional shift to attend the demand. Using chronoanalysis and PCP information, it was observed that by reducing the set up to 30 min, those pieces of equipment could work just in one shift. Then, it was applied the Kaizen SMED (Single minute exchange of die), changing intern to external activities and redistributing activities to be executed in parallel. The results showed a reduction of set up time from 61min21s to 29min42s, allowing to eliminate a work shift. After the implementation of these improvements, the managers decide to adopt the lean philosophy as the company´s new management model