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Aplicação da Metodologia SMED para Otimização do Processo de Extrusão numa Empresa de Fabrico de Fio Elétrico
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| 3.44 MB | Adobe PDF |
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Abstract(s)
Esta dissertação tem como objetivo a otimização do processo de extrusão de fio elétrico
numa empresa do setor automóvel, através da aplicação de ferramentas da filosofia Lean
Manufacturing, com especial destaque para a metodologia SMED (Single Minute Exchange
of Die). O trabalho foi desenvolvido no âmbito de um estágio curricular realizado na Coficab
Portugal, uma organização dedicada à produção de cabos para a indústria automóvel, e
surge como resposta à necessidade de melhorar os indicadores operacionais da linha de extrusão.
O projeto teve como foco principal o aumento do running time da linha, um dos indicadores-chave de desempenho (KPI) definidos pela empresa, e cuja melhoria influencia diretamente outros parâmetros, como o speed efficiency e a geração de scrap. A investigação iniciou-se com um diagnóstico detalhado do processo atual, recorrendo à observação direta, à
cronometragem manual dos setups e à análise de dados históricos. Esta fase permitiu identificar ineficiências relacionadas com a ausência de padronização, a execução descoordenada das atividades e a má preparação dos recursos necessários às mudanças de produto.
Com base na metodologia SMED, foi realizada uma proposta de reorganização dos procedimentos de setup, assente na distinção entre tarefas internas e externas, eliminação de desperdícios e definição de trabalho padronizado. A implementação das melhorias permitiu
reduzir significativamente os tempos de setup, com ganhos médios de 35% nas mudanças
de bobine e 56% nas mudanças de secção. Estes resultados contribuíram para o aumento
efetivo do tempo produtivo da linha, validando a eficácia da abordagem adotada.
A experiência demonstrou que, mesmo num ambiente industrial consolidado, a aplicação
estruturada de ferramentas lean pode gerar melhorias significativas e sustentadas, desde
que acompanhada pelo envolvimento das equipas operacionais e por uma análise crítica do
processo. O trabalho realizado evidencia o potencial de replicação desta metodologia noutros contextos produtivos e reforça a importância da melhoria contínua como pilar da competitividade industrial.
This dissertation aims to optimize the wire extrusion process in an automotive industry company through the application of Lean Manufacturing tools, with particular focus on the SMED (Single Minute Exchange of Die) methodology. The project was developed during a curricular internship at Coficab Portugal, a company specialized in the production of cables for the automotive sector, and responds to the need to improve the operational performance indicators of the extrusion line. The main focus of the study was to increase the line's running time, a key performance indicator (KPI) defined by the company, whose improvement directly influences other metrics such as speed efficiency and scrap generation. The research began with a detailed diagnosis of the current process, using direct observation, manual timing of setup activities, and historical data analysis. This phase identified inefficiencies related to the lack of standardization, uncoordinated execution of tasks, and poor preparation of resources during product changeovers. Based on the SMED methodology, a reorganization of setup procedures was proposed, grounded on the separation of internal and external tasks, waste elimination, and the definition of standardized work. The implementation of these improvements led to significant reductions in setup times, with average gains of 35% in bobbin changes and 56% in section changes. These results contributed to an effective increase in productive time, validating the approach adopted. The experience demonstrated that, even in a mature industrial environment, the structured application of lean tools can deliver significant and sustainable improvements, provided it is supported by operator involvement and critical process analysis. This work highlights the potential to replicate this methodology in other production contexts and reinforces the importance of continuous improvement as a pillar of industrial competitiveness.
This dissertation aims to optimize the wire extrusion process in an automotive industry company through the application of Lean Manufacturing tools, with particular focus on the SMED (Single Minute Exchange of Die) methodology. The project was developed during a curricular internship at Coficab Portugal, a company specialized in the production of cables for the automotive sector, and responds to the need to improve the operational performance indicators of the extrusion line. The main focus of the study was to increase the line's running time, a key performance indicator (KPI) defined by the company, whose improvement directly influences other metrics such as speed efficiency and scrap generation. The research began with a detailed diagnosis of the current process, using direct observation, manual timing of setup activities, and historical data analysis. This phase identified inefficiencies related to the lack of standardization, uncoordinated execution of tasks, and poor preparation of resources during product changeovers. Based on the SMED methodology, a reorganization of setup procedures was proposed, grounded on the separation of internal and external tasks, waste elimination, and the definition of standardized work. The implementation of these improvements led to significant reductions in setup times, with average gains of 35% in bobbin changes and 56% in section changes. These results contributed to an effective increase in productive time, validating the approach adopted. The experience demonstrated that, even in a mature industrial environment, the structured application of lean tools can deliver significant and sustainable improvements, provided it is supported by operator involvement and critical process analysis. This work highlights the potential to replicate this methodology in other production contexts and reinforces the importance of continuous improvement as a pillar of industrial competitiveness.
Description
Keywords
Extrusão Indicadores-Chave de Desempenho Lean Manufacturing Smed