The use of virtual reality as an e-training tool for change of die in stamping presses: a case study on automotive industry

Detalhes bibliográficos
Autor(a) principal: Monteiro, Jorge Rafael Mendes
Data de Publicação: 2022
Tipo de documento: Dissertação
Idioma: eng
Título da fonte: Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos)
Texto Completo: http://hdl.handle.net/10773/37849
Resumo: The paradigm of Industry 4.0 has emerged to change the way the work is done in the production area. The technologies associated with the fourth industrial revolution are varied and promote the automation of processes, while providing innovative solutions to several problems in organisational contexts. Lean Manufacturing is a philosophy that was originated at the end of the 20th century in Japan, based on Toyota's production system. The main objective of this philosophy is the elimination of all types of waste in productive processes, using various tools to achieve this goal. There is a bilateral relationship between Industry 4.0 and Lean Manufacturing: since Industry 4.0 automates production processes, increasing their output, it is important to have optimised processes from the point of view of the Lean philosophy in order not to increase the waste associated with the operation. On the other hand, in the opposite direction, Lean tools can benefit largely from the application of 4.0 technologies, originating the so-called Lean 4.0. In the current productive context, die changes are considered activities without added value, although they are necessary for production. Since they do not add any value, the objective of each and every company is to reduce the time consumed in these activities and, in the company where this project was developed, this topic is also a concern, so this reduction is also desired. Virtual reality is one of the technologies that fits in the scope of Industry 4.0. Making use of the Action Research methodology, this work intends to make an unconventional approach to Single Minute Exchange of Die, a Lean tool that aims to obtain fast die changes. E-Virtual Training has the goal of decreasing the machine stop time for training in die change by 50%, also analysing ergonomic constraints during the change process. The aim is to emulate the real environment in virtual reality and to make the transition from physical training in die change, which requires machine stoppage, to hybrid training - 50% virtual, 50% physical. This way, there are two savings for the company: one generated by the increase in machine availability due to the reduction in downtime for training and a second one obtained due to the reduction in the time needed to perform a change of die, which also contributes to the increase in machine availability. This second saving will be further boosted if one manages to reduce the physical component of training even more and increase the virtual component.
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spelling The use of virtual reality as an e-training tool for change of die in stamping presses: a case study on automotive industryVirtual realityChange of dieOperatorTrainingStamping pressLean manufacturingSMEDIndustry 4.0The paradigm of Industry 4.0 has emerged to change the way the work is done in the production area. The technologies associated with the fourth industrial revolution are varied and promote the automation of processes, while providing innovative solutions to several problems in organisational contexts. Lean Manufacturing is a philosophy that was originated at the end of the 20th century in Japan, based on Toyota's production system. The main objective of this philosophy is the elimination of all types of waste in productive processes, using various tools to achieve this goal. There is a bilateral relationship between Industry 4.0 and Lean Manufacturing: since Industry 4.0 automates production processes, increasing their output, it is important to have optimised processes from the point of view of the Lean philosophy in order not to increase the waste associated with the operation. On the other hand, in the opposite direction, Lean tools can benefit largely from the application of 4.0 technologies, originating the so-called Lean 4.0. In the current productive context, die changes are considered activities without added value, although they are necessary for production. Since they do not add any value, the objective of each and every company is to reduce the time consumed in these activities and, in the company where this project was developed, this topic is also a concern, so this reduction is also desired. Virtual reality is one of the technologies that fits in the scope of Industry 4.0. Making use of the Action Research methodology, this work intends to make an unconventional approach to Single Minute Exchange of Die, a Lean tool that aims to obtain fast die changes. E-Virtual Training has the goal of decreasing the machine stop time for training in die change by 50%, also analysing ergonomic constraints during the change process. The aim is to emulate the real environment in virtual reality and to make the transition from physical training in die change, which requires machine stoppage, to hybrid training - 50% virtual, 50% physical. This way, there are two savings for the company: one generated by the increase in machine availability due to the reduction in downtime for training and a second one obtained due to the reduction in the time needed to perform a change of die, which also contributes to the increase in machine availability. This second saving will be further boosted if one manages to reduce the physical component of training even more and increase the virtual component.O paradigma da Indústria 4.0 surgiu para modificar a forma como se trabalha no setor da produção. As tecnologias associadas à quarta revolução industrial são variadas e promovem a automatização de processos, ao mesmo tempo que fornecem soluções inovadoras para diversos problemas em contexto organizacional. Por sua vez, o Lean Manufacturing é uma filosofia que teve a sua génese no final do século XX, no Japão, tendo como base o sistema de produção da Toyota. O principal objetivo desta filosofia assenta na eliminação de todos os tipos de desperdício nos processos produtivos, servindo-se do uso de diversas ferramentas para alcançar esse fim. Existe, atualmente, uma relação bilateral entre a Indústria 4.0 e o Lean Manufacturing: uma vez que a Indústria 4.0 automatiza os processos produtivos, procedendo ao aumento do seu output, é importante que se tenham processos otimizados do ponto de vista da filosofia Lean no sentido de não potenciar o aumento do desperdício associado à operação. Por sua vez, em sentido oposto, as ferramentas Lean podem beneficiar em grande escala da aplicação das tecnologias 4.0, dando origem ao chamado Lean 4.0. No contexto produtivo atual, as trocas de ferramenta são consideradas atividades sem valor acrescentado, embora sejam necessárias à produção. Uma vez que não acrescentam qualquer valor, o objetivo de toda e qualquer empresa passa por reduzir o tempo que se consome nestas atividades e, na empresa onde se desenvolveu este projeto, este tópico também é um foco de preocupação, pelo que esta redução também é desejada. A realidade virtual é uma das tecnologias que se enquadra no âmbito da Indústria 4.0. Fazendo uso da metodologia Action Research, este trabalho pretende fazer uma abordagem pouco convencional ao SMED, uma ferramenta Lean que visa obter trocas de ferramenta rápidas, e diminuir o tempo de paragem de máquina para formação em troca de ferramenta em 50%, analisando também constrangimentos a nível de ergonomia durante o processo de troca. Pretende-se emular o ambiente real em realidade virtual e fazer a transição de formação física em troca de ferramenta, que exige paragem de máquina, para uma formação híbrida – 50% no ambiente virtual, 50% física. Deste modo, existem dois savings para a empresa: aquele que é gerado pelo aumento da disponibilidade da máquina devido à diminuição das paragens para formação e um segundo obtido devido à diminuição do tempo de execução da troca de ferramenta, o que também contribui para o aumento da disponibilidade de máquina. Este segundo saving será alavancado a partir do momento em que se consiga diminuir ainda mais a componente física da formação e se aumente a componente virtual.2023-05-23T10:16:27Z2022-07-25T00:00:00Z2022-07-25info:eu-repo/semantics/publishedVersioninfo:eu-repo/semantics/masterThesisapplication/pdfhttp://hdl.handle.net/10773/37849engMonteiro, Jorge Rafael Mendesinfo:eu-repo/semantics/openAccessreponame:Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos)instname:Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informaçãoinstacron:RCAAP2024-02-22T12:12:16Zoai:ria.ua.pt:10773/37849Portal AgregadorONGhttps://www.rcaap.pt/oai/openaireopendoar:71602024-03-20T03:08:02.353322Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) - Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informaçãofalse
dc.title.none.fl_str_mv The use of virtual reality as an e-training tool for change of die in stamping presses: a case study on automotive industry
title The use of virtual reality as an e-training tool for change of die in stamping presses: a case study on automotive industry
spellingShingle The use of virtual reality as an e-training tool for change of die in stamping presses: a case study on automotive industry
Monteiro, Jorge Rafael Mendes
Virtual reality
Change of die
Operator
Training
Stamping press
Lean manufacturing
SMED
Industry 4.0
title_short The use of virtual reality as an e-training tool for change of die in stamping presses: a case study on automotive industry
title_full The use of virtual reality as an e-training tool for change of die in stamping presses: a case study on automotive industry
title_fullStr The use of virtual reality as an e-training tool for change of die in stamping presses: a case study on automotive industry
title_full_unstemmed The use of virtual reality as an e-training tool for change of die in stamping presses: a case study on automotive industry
title_sort The use of virtual reality as an e-training tool for change of die in stamping presses: a case study on automotive industry
author Monteiro, Jorge Rafael Mendes
author_facet Monteiro, Jorge Rafael Mendes
author_role author
dc.contributor.author.fl_str_mv Monteiro, Jorge Rafael Mendes
dc.subject.por.fl_str_mv Virtual reality
Change of die
Operator
Training
Stamping press
Lean manufacturing
SMED
Industry 4.0
topic Virtual reality
Change of die
Operator
Training
Stamping press
Lean manufacturing
SMED
Industry 4.0
description The paradigm of Industry 4.0 has emerged to change the way the work is done in the production area. The technologies associated with the fourth industrial revolution are varied and promote the automation of processes, while providing innovative solutions to several problems in organisational contexts. Lean Manufacturing is a philosophy that was originated at the end of the 20th century in Japan, based on Toyota's production system. The main objective of this philosophy is the elimination of all types of waste in productive processes, using various tools to achieve this goal. There is a bilateral relationship between Industry 4.0 and Lean Manufacturing: since Industry 4.0 automates production processes, increasing their output, it is important to have optimised processes from the point of view of the Lean philosophy in order not to increase the waste associated with the operation. On the other hand, in the opposite direction, Lean tools can benefit largely from the application of 4.0 technologies, originating the so-called Lean 4.0. In the current productive context, die changes are considered activities without added value, although they are necessary for production. Since they do not add any value, the objective of each and every company is to reduce the time consumed in these activities and, in the company where this project was developed, this topic is also a concern, so this reduction is also desired. Virtual reality is one of the technologies that fits in the scope of Industry 4.0. Making use of the Action Research methodology, this work intends to make an unconventional approach to Single Minute Exchange of Die, a Lean tool that aims to obtain fast die changes. E-Virtual Training has the goal of decreasing the machine stop time for training in die change by 50%, also analysing ergonomic constraints during the change process. The aim is to emulate the real environment in virtual reality and to make the transition from physical training in die change, which requires machine stoppage, to hybrid training - 50% virtual, 50% physical. This way, there are two savings for the company: one generated by the increase in machine availability due to the reduction in downtime for training and a second one obtained due to the reduction in the time needed to perform a change of die, which also contributes to the increase in machine availability. This second saving will be further boosted if one manages to reduce the physical component of training even more and increase the virtual component.
publishDate 2022
dc.date.none.fl_str_mv 2022-07-25T00:00:00Z
2022-07-25
2023-05-23T10:16:27Z
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