Screw torque traceability control: industrial application

This paper analyses a new screw torque traceability control procedure designed for an operation in a car audio workstation. First the detection score at a Failure Mode and Effects Analysis (FMEA) indicated which process improvement were needed. On the sequence, data was collected to evaluate performance indicators. Finally, specific actions were executed based on the improvement plan. As result, the FMEA detection score improved from 7 to 3, the run rate increased from 12 to 16 products/h and defects caused by improper screwing were eliminated. This research contributes to disseminate a practical application of a screw torque traceability control

Digital technologies review for manufacturing processes

It is apparent the industrial processes transformations caused by industry 4.0 are in advance in some countries like China, Japan, Germany and United States. But, in return, the developing countries, as the emergent Brazil, seem like to have a long way to achieve digital era. Considering manufacturing processes as the starting point the rise of industry 4.0, this research aims to show a review about the most important technologies used in smart manufacturing, including the main challenges to implement it at Brazil. The papers were collected from Web of Science (WoS), comprising 114 articles and 2 books to underpin this study. This exploratory research resulted in the presentation of some challenges faced by Brazilian industry to join the new industrial era, such as poor technological infrastructure, besides lack of investment in technologies and training of qualified people. Even though the primary motivation of this research was to present a panorama of smart manufacturing for Brazil, this study results contributes to the most of emergent countries, bringing together general concepts and addressing practical applications developed by several researchers from the international academic community

Modelo de reprogramação de produção em flow shop híbrido unidirecional integrando fabricante por contrato e seus clientes

Tese (doutorado) - Universidade Federal de Santa Catarina, Centro Tecnológico, Programa de Pós-Graduação em Engenharia de Produção, Florianópolis, 2020.Fabricantes por contrato (Contract Manufacturer, CM) normalmente programam sua produção considerando separadamente os requerimentos e restrições de cada indústria compradora. Os planejadores dos CMs podem coordenar a programação de um ou mais clientes e, quando surge a necessidade de reprogramação, analisam o planejamento das linhas dedicadas ou compartilhadas entre seus diversos produtos, o que pode gerar a necessidade de renegociação de compromissos de entrega (prazos e quantidades) com diversos clientes. As desvantagens dessa estratégia são as dificuldades de avaliar as oportunidades de melhor utilização da capacidade da planta, além da eventual necessidade de novos acordos para reajustes na entrega que envolvam mais de um cliente, sendo ainda mais crítico no nível operacional (short term). Essa situação limita a qualidade da reprogramação de produção à experiência e habilidade de negociação dos planejadores. Nesse contexto, o objetivo dessa pesquisa é propor um novo modelo de reprogramação de produção em flow shop híbrido unidirecional para abordar a integração, em contextos dinâmicos, de um fabricante por contrato, que lida com a execução da produção e controle de estoque, e seus clientes industriais, responsáveis pelo processo de planejamento da entrega. O estudo foi estruturado em 3 (três) fases: (i) definição das oportunidades e problema de pesquisa, realizada por meio de revisão sistemática de literatura, (ii) construção do modelo conceitual, desenhado a partir do problema empírico de conectar um CM e seus clientes industriais e (iii) modelagem de um flow shop híbrido real usando abordagem multimétodo, combinando eventos discretos e sistema baseado em agentes para lidar com o problema no nível operacional. Os resultados evidenciam o pioneirismo de uma pesquisa sobre reprogramação no nível operacional com integração entre indústrias, o modelo proposto melhora os desempenhos tanto na execução da produção na fábrica, quanto no nível de atendimento aos compromissos de entrega ao cliente e também promove a parceria entre os envolvidos, pois o plano de entrega com flexibilidade para ajustes e a pré-disposição de análise para modificações na programação durante o período congelado, diminui a necessidade de negociações entre as empresas, tanto para os reprogramações eventuais quanto para os reprogramações periódicas. Futuramente, espera-se a aplicação prática em chão de fábrica, com o desenvolvimento de um sistema computacional para ajuste autônomo de reprogramação de produção em nível operacional, o que liberaria o planejador para focar em questões de planejamento tático e estratégico. Embora essa pesquisa tenha sido motivada para resolver um problema de reprogramação de produção em Serviço de Manufatura por Contrato (Contract Manufacturing Service, CMS), a abordagem pode ser aplicada a qualquer parceria B2B.Abstract: Contract Manufacturer (CM) usually schedule their production considering the requirements and constraints of each purchasing industry separately. The CM planners can coordinate the scheduling of one or more customers and, when the need for rescheduling arises, they analyze the schedules of the dedicated or shared lines among their various products, which may address the need to renegotiate delivery commitments (deadlines and quantities). The drawbacks of this strategy are the difficulties of evaluating the opportunities for better utilization of the plant capacity, besides the possible need for new agreements for delivery readjustments that involve more than one customer, especially in operational level (short term). This situation limits the quality of production rescheduling to the experience and negotiation skills of planners. In this context, this research aims to propose a novel unidirectional hybrid flow shop rescheduling model to address the integration in dynamic contexts, of a contract manufacturer, who handles production execution and inventory control, and their industrial customers, who are in charge of the delivery planning process. The study was structured in 3 (three) phases: (i) Definition of opportunities and research problem, based on a systematic literature review; (ii) Conceptual model building, emerged from the empirical problem of connecting a contract manufacturer with its industrial customers and (iii) Modeling of a real hybrid flow shop using a multi-method approach, combining discretes events and agent-based simulation to handle the problem in a operational level. The results highlight the research pioneerism about rescheduling at operational level integrating two industries; the model improve the overall production and delivery performance and, also foster the partnership between the involved stakeholders. In the future, it is expected a practical application in a shop floor, considering a develoment of a computational program for autonomous adjustments of a production rescheduling in operational level, releasing the planner to focus on tactical and strategic scheduling issues. Even though the primary motivation of this research was to solve a production rescheduling issue in Contract Manufacturing Service, the approach can be applied in any B2B partnership

Screw torque traceability control: industrial application

This paper analyses a new screw torque traceability control procedure designed for an operation in a car audio workstation. First the detection score at a Failure Mode and Effects Analysis (FMEA) indicated which process improvement were needed. On the sequence, data was collected to evaluate performance indicators. Finally, specific actions were executed based on the improvement plan. As result, the FMEA detection score improved from 7 to 3, the run rate increased from 12 to 16 products/h and defects caused by improper screwing were eliminated. This research contributes to disseminate a practical application of a screw torque traceability control