Implementação de melhorias no arranjo físico e redução de desperdícios no processo de preparação de tubos em uma empresa do setor automotivo

Abstract

This study sought to apply improvements for the waste reduction in a process of an automotive industry of heavy trucks, as well as make layout changes and propose a new layout considering a capacity increasing. The process chosen for the study is a sub-assembly area of this company, located in Ponta Grossa, PR. In this process, the pipes that belongs to the pneumatic system and other assemblies of the vehicles are printed and pre-assembled. The main focus of this paper is to reduce the waste of movement and improve the flow of the process, creating a visual management and ensuring the quality. The topics covered in the bibliography of this paper involves the definition and concepts of assembly line, types of layout, production processes mapping and Toyota Production System. In the study carried out "in loco", the current piping production process was analyzed, observing gaps where improvements could be applied, foreseeing the implementation of the Pull System concepts for the production and the provision of the pipes to the assemblies’ processes. The study also included the identification of problems, and the gains and advantages about implementing these changes in the productive process, comparing the previous and future situation by presenting the results, which ones were very satisfactory, reducing specially the waste of movement and saving by this way approximately 40% of the time in the process. The purpose of a new layout was also already implemented at the beginning of 2018 due to the capacity increasing and it has been shown very efficient, proofing the importance about a good layout planning for the process.