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Criação e teste de um sistema Pull para o abastecimento interno de uma secção-piloto – Caso de estudo da indústria de polimentos
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O estágio teve como principal objetivo a identificação e análise dos principais problemas e desperdícios no processo de abastecimento interno das secções da empresa HMM – Fábrica do Fundão, permitindo posteriormente criar oportunidades de melhoria. Em primeiro lugar, foi utilizada a metodologia Six-Sigma DMAIC (Define, Measure, Analyze, Improve and Control) para organizar e calendarizar o projeto-piloto dividido em duas fases: criação de supermercados Pull na secção-piloto; projeto de um sistema de abastecimento interno para a secção-piloto, através de um comboio ou veículo logístico interno. Durante a fase measure foram identificados os desperdícios associados ao transporte, inventário, movimentações e defeitos. Adicionalmente, a adoção de um sistema Push na logística interna da empresa combinado com as características do carro utilizado para a distribuição interna de caixas e a inexistência de rotas claramente definidas relativamente a tempos, percursos, paragens não programadas e quantidade de caixas a distribuir por rota culmina em atrasos, podendo dar origem à falta ou ao excesso de matéria-prima nas secções. Por fim, através da implementação de um teste à primeira fase do projeto-piloto obtiveram-se melhorias na organização e rastreabilidade das ordens de produção, reduziu-se o espaço ocupado pelos antigos racks em 0,66 m2 , criaram-se e implementaram-se identificações para os racks e para os postos de trabalho, para que sejam visíveis por qualquer entidade, criaram-se soluções para reduzir os riscos associados à movimentação manual de caixas e para permitir uma gestão total dos espaços do supermercado Pull. A implementação total das duas fases do projeto-piloto permitiria resumidamente obter uma redução: dos lead times; da quantidade de caixas à entrada na secção-piloto em 36%; e do número de rotas diárias em 8%. As ferramentas Lean implementadas demonstraram uma eficácia significativa na otimização da logística interna, reduzindo desperdícios, melhorando fluxos de materiais e estabelecendo bases sólidas para a melhoria contínua do desempenho organizacional.
The main objective of this report is to identify and analyse the major problems and waste in the internal supply process of the sections at HMM. As a result, it was possible to create improvement opportunities. In the first place, the Six Sigma DMAIC (Define, Measure, Analyze, Improve and Control) methodology was used to organise and schedule the pilot project, which was divided into two phases: setting-up of supermarket pull system in the pilot section; design of an internal supply system for the pilot section, using an internal logistic vehicle or train. Secondly, during the measure phase the following waste was identified: transportation, overstocking, movements and defects. The push system used in the company´s internal logistics process, the features of the trolley which is used for internal distribution of boxes, and the lack of defined routes regarding to cycle time, track, unscheduled stops and the quantity of boxes to be distributed per route, results in delays which might cause a shortage or excess of raw materials in the sections. In conclusion, the test of the first phase of the pilot project resulted in a better organization and traceability of production orders, reduced the space taken up by the old racks by 0,66 square metres and identifications for racks and workstations were created to allow them to be easily visible to any entity. Moreover, solutions were created to reduce a physical effort of employees during the manual handling of boxes and to enable total management of the spaces in the supermarket pull. The full implementation of the two phases of the pilot project would briefly result in a reduction in: lead times; the number of boxes entering in the pilot section by 36%; and the number of daily routes by 8%. The implemented Lean tools demonstrated significant effectiveness in internal logistics optimization, reducing waste, improving material flows and establishing solid foundations for continuous improvement of organizational performance.
The main objective of this report is to identify and analyse the major problems and waste in the internal supply process of the sections at HMM. As a result, it was possible to create improvement opportunities. In the first place, the Six Sigma DMAIC (Define, Measure, Analyze, Improve and Control) methodology was used to organise and schedule the pilot project, which was divided into two phases: setting-up of supermarket pull system in the pilot section; design of an internal supply system for the pilot section, using an internal logistic vehicle or train. Secondly, during the measure phase the following waste was identified: transportation, overstocking, movements and defects. The push system used in the company´s internal logistics process, the features of the trolley which is used for internal distribution of boxes, and the lack of defined routes regarding to cycle time, track, unscheduled stops and the quantity of boxes to be distributed per route, results in delays which might cause a shortage or excess of raw materials in the sections. In conclusion, the test of the first phase of the pilot project resulted in a better organization and traceability of production orders, reduced the space taken up by the old racks by 0,66 square metres and identifications for racks and workstations were created to allow them to be easily visible to any entity. Moreover, solutions were created to reduce a physical effort of employees during the manual handling of boxes and to enable total management of the spaces in the supermarket pull. The full implementation of the two phases of the pilot project would briefly result in a reduction in: lead times; the number of boxes entering in the pilot section by 36%; and the number of daily routes by 8%. The implemented Lean tools demonstrated significant effectiveness in internal logistics optimization, reducing waste, improving material flows and establishing solid foundations for continuous improvement of organizational performance.
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Palavras-chave
Filosofia Lean Logística Logística Lean Logística interna Inventário Sistema Push Sistema Pull Kanban Supermercado Pull Mizusumashi Milk Run Lean Philosophy Logistics Lean logistics Internal logistics process Inventory Push system Pull system Supermarket pull system