Analysis and optimization of the production process

• Autor(a) principal: Maia, Bruno Miguel Vieira
• Data de Publicação: 2018
• Tipo de documento: Dissertação
• Idioma: eng
• Título da fonte: Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos)
• Texto Completo: http://hdl.handle.net/10400.22/13898
• topic: Production process; Analysis; Workstation control; Lean tools; Improvement; 5S; VSM; PDCA; Processo produtivo; Análise; Controlo de posto de trabalho; Ferramentas Lean; Melhoria; Gestão Industrial

This dissertation describes an approach to the improvement of the production process of an automobile plastic part. The improvement of this productive process intends to increase labor utilization, reducing all related costs and activities along the process such as semi-product’s stocking, as well as reduce the logistic flows and the existing components’ assembly workstation of the analyzed part. The methodology used in this project focus on the application of tools to analyze and improve productive processes, such as the process diagram, the spaghetti diagram, PDCA, tasks’ time registration and VSM (Value Stream Mapping). The use of the process and spaghetti diagrams and the time registration tools allowed clearer information about the current status of the productive process. The analysis of the current status reveals that there is a great amount of waste in both workstations - injection and assembly - on what regards workers’ time occupation. The application of PDCA with its actions’ plan allows the change to happen successfully. The intention of the project is to show that the current status can always be improved using the correct tools to analyze and propose changes which will in the short term bring savings to the company. The second part of the dissertation describes the creation and implementation of a second assembly line, which has the same way of working as the first one, but with improvements to overcome the failures found in the first stage. The reason for the creation of this second assembly line is the fact that the company is not able to respond to the increased demand for the following months / years with only one assembly line.