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Advisor(s)
Abstract(s)
A variedade de produtos alimentícios tem tido um crescimento exponencial, a acompanhar um mercado cada vez mais fragmentado e especializado. A produção que em tempos foi em massa, procura agora dar resposta rápida a um cliente mais exigente e especializado, entregando um produto com valor. A presente dissertação tem como principal objetivo aumentar a eficácia global da unidade de engarrafamento da Quinta and Vineyard Blottlers – Vinhos S.A., diminuindo ou eliminando os principais desperdícios, com recurso à implementação de ferramentas Lean. Depois de efetuado um ponto de situação de uma das linhas de engarrafamento, verificou-se que o elevado número e duração do setup são a principal razão das paragens dos equipamentos, tendo provocado um total de 380,5 horas de paragem, em período laboral. Foram aplicadas três ferramentas Lean: SMED, 5S e normalização. O SMED foi feito para três setups diferentes e permitiu reduzir o tempo total em alguns equipamentos, com as ações de melhoria propostas. No âmbito da gestão visual (5S) foram implementadas algumas medidas para facilitar o fluxo de trabalho, nomeadamente, o desenvolvimento de instruções de trabalho, uma estrutura para dispor as peças das rotuladoras e remoção de todos os objetos desnecessários em cada setor. Foi ainda elaborada uma ficha técnica com toda a informação necessária para a execução de um determinado produto, desde o modelo de garrafa ao mosaico da paletização, uma vez que a informação em falta na guia de produção provocava paragens na linha de engarrafamento. Ainda assim, com a aplicação destas ferramentas, verificou-se uma diminuição de 4,13 pontos percentuais no valor da Eficácia Global do Equipamento nos meses de setembro, outubro e novembro de 2023, face a 2022. Para além disso, o tempo médio de setup teve um acréscimo de 1 minuto, comparando os mesmos meses de 2023, face a 2022. Os resultados obtidos não foram os esperados, contudo, não significa que as ferramentas aplicadas não tiveram um impacto positivo no processo de engarrafamento. Há inúmeras variáveis inerentes à indústria do vinho, nomeadamente a grande variedade de produtos que obriga a diferentes setups diários, difíceis de padronizar. Há ainda ocorrências não planeadas que motivam a paragem das linhas, como por exemplo, avarias, qualidade das matérias-primas, erro humano, entre outros.
The variety of food products has seen exponential growth, in line with an increasingly fragmented and specialized market. Production, which was once mass, now seeks to respond quickly to a more demanding and specialized customer, delivering a product with value. The main objective of this dissertation is to improve the overall effectiveness of the Quinta and Vineyard Bottlers – Vinhos S.A. bottling unit, reducing, or eliminating the main waste, using the implementation of Lean tools. After taking stock of one of the bottling lines (line 12), it was found that the high number and duration of setup are the main reason for equipment downtime, causing a total of 380,5 hours of downtime, during working hours. Three Lean tools were applied: SMED, 5S and normalization. SMED was made for three different setups and allowed the total time on some equipment to be reduced, with the proposed improvement actions. In the area of visual management (5S), some measures were implemented to facilitate the workflow, namely, the development of work instructions, a display for labelling machine parts and removal of all unnecessary objects in each sector. A technical sheet was also drawn up with all the information necessary for the execution of a given product, from the bottle model to the palletization mosaic, as missing information in the production guide caused downtime on the bottling line. Even so, with the application of these tools, there was a decreased of 4,13 percentage points in the Overall Equipment Effectiveness value in the months of September, October, and November 2023, compared to 2022. Furthermore, the average setup time had an increase of 1 minute, comparing the same months of 2023, compared to 2022. The results obtained were unsatisfactory, however, this does not mean that the tools applied did not have a positive impact on the bottling process. There are countless variables inherent to the wine industry, namely the wide variety of products that require different daily setups, which are difficult to standardize. There are also unplanned occurrences that cause downtimes, such as breakdowns, quality of raw materials, human error, among others.
The variety of food products has seen exponential growth, in line with an increasingly fragmented and specialized market. Production, which was once mass, now seeks to respond quickly to a more demanding and specialized customer, delivering a product with value. The main objective of this dissertation is to improve the overall effectiveness of the Quinta and Vineyard Bottlers – Vinhos S.A. bottling unit, reducing, or eliminating the main waste, using the implementation of Lean tools. After taking stock of one of the bottling lines (line 12), it was found that the high number and duration of setup are the main reason for equipment downtime, causing a total of 380,5 hours of downtime, during working hours. Three Lean tools were applied: SMED, 5S and normalization. SMED was made for three different setups and allowed the total time on some equipment to be reduced, with the proposed improvement actions. In the area of visual management (5S), some measures were implemented to facilitate the workflow, namely, the development of work instructions, a display for labelling machine parts and removal of all unnecessary objects in each sector. A technical sheet was also drawn up with all the information necessary for the execution of a given product, from the bottle model to the palletization mosaic, as missing information in the production guide caused downtime on the bottling line. Even so, with the application of these tools, there was a decreased of 4,13 percentage points in the Overall Equipment Effectiveness value in the months of September, October, and November 2023, compared to 2022. Furthermore, the average setup time had an increase of 1 minute, comparing the same months of 2023, compared to 2022. The results obtained were unsatisfactory, however, this does not mean that the tools applied did not have a positive impact on the bottling process. There are countless variables inherent to the wine industry, namely the wide variety of products that require different daily setups, which are difficult to standardize. There are also unplanned occurrences that cause downtimes, such as breakdowns, quality of raw materials, human error, among others.
Description
Keywords
Vinho SMED 5S Normalização OEE Wine Standardization