Loading...
Publication
Aplicação da filosofia Lean na melhoria contínua do processo produtivo do tabaco
| Name: | Description: | Size: | Format: | |
|---|---|---|---|---|
| 2.56 MB | Adobe PDF |
Authors
Advisor(s)
Abstract(s)
As práticas de manutenção são fundamentais para garantir a eficiência operacional e a longevidade dos equipamentos e processos nas empresas. No contexto da melhoria contínua, elas desempenham um papel crucial ao prevenir falhas e interrupções inesperadas, permitindo que as operações fluam de maneira mais previsível e confiável. Além disso, a manutenção regular e preventiva reduz custos com reparos emergenciais e perda de produtividade, melhorando a rentabilidade. Empresas que adotam práticas de manutenção eficazes, tendem a se destacar no mercado pela sua confiabilidade e capacidade de atender aos prazos e demandas dos clientes, consolidando uma imagem de excelência. Essas práticas também promovem a segurança no ambiente de trabalho, evitando acidentes que possam comprometer a integridade dos funcionários e impactar negativamente a reputação da empresa. Ao otimizar o desempenho dos ativos, as organizações podem se adaptar rapidamente às mudanças de mercado e inovações tecnológicas, mantendo-se competitivas. Contudo, empresas que investem em manutenção demonstram compromisso com a sustentabilidade, ao prolongar a vida útil dos seus recursos, o que reforça uma imagem positiva perante clientes e investidores, e fortalece a sua posição no mercado. Este trabalho investiga a aplicação da filosofia Lean na melhoria contínua do processo produtivo de uma fábrica de cigarros em Portugal. Utilizando um estudo de caso, a pesquisa examina a implementação de práticas de Manutenção Produtiva Total (TPM) e Manutenção Autônoma, com foco na otimização dos processos produtivos e na redução de desperdícios. O estudo apresenta uma análise dos indicadores de desempenho, como OEE e Uptime, antes e após a implementação das práticas Lean. Os resultados mostram melhorias significativas na eficiência operacional, que passou de 88,08% para 96,30%, qualidade dos produtos e redução de 8,55% para 2,49%, das paragens não planeadas. Além disso, são discutidas as limitações e desafios enfrentados durante o processo de implementação, como a necessidade de treinamento intensivo e mudança cultural dos operadores. Este estudo contribui para a literatura, ao evidenciar a eficácia das práticas Lean na indústria do tabaco, propondo um caminho para a melhoria contínua e a excelência operacional.
Abstract Maintenance practices are essential to ensuring operational efficiency and the longevity of equipment and processes in companies. In the context of continuous improvement, they play a crucial role in preventing failures and unexpected interruptions, allowing operations to flow in a more predictable and reliable manner. Furthermore, regular and preventive maintenance reduces costs associated with emergency repairs and productivity losses, enhancing profitability. Companies that adopt effective maintenance practices tend to stand out in the market for their reliability and ability to meet deadlines and customer demands, consolidating an image of excellence. These practices also promote workplace safety, preventing accidents that could compromise employee integrity and negatively impact the company's reputation. By optimizing asset performance, organizations can quickly adapt to market changes and technological innovations, remaining competitive. Moreover, companies that invest in maintenance demonstrate a commitment to sustainability by extending the useful life of their resources, reinforcing a positive image to customers and investors, and strengthening their position in the market. This paper investigates the application of Lean philosophy in the continuous improvement of the production process of a cigarette factory in Portugal. Using a case study, the research examines the implementation of Total Productive Maintenance (TPM) and Autonomous Maintenance practices, focusing on optimizing production processes and reducing waste. The study presents an analysis of performance indicators, such as OEE and Uptime, before and after the implementation of Lean practices. The results show significant improvements in operational efficiency, which increased from 88.08% to 96.30%, product quality, and a reduction in unplanned stoppages from 8.55% to 2.49%. Additionally, the limitations and challenges faced during the implementation process are discussed, such as the need for intensive training and cultural change among operators. This study contributes to the literature, by highlighting the effectiveness of Lean practices in the tobacco industry, proposing a path for continuous improvement and operational excellence.
Abstract Maintenance practices are essential to ensuring operational efficiency and the longevity of equipment and processes in companies. In the context of continuous improvement, they play a crucial role in preventing failures and unexpected interruptions, allowing operations to flow in a more predictable and reliable manner. Furthermore, regular and preventive maintenance reduces costs associated with emergency repairs and productivity losses, enhancing profitability. Companies that adopt effective maintenance practices tend to stand out in the market for their reliability and ability to meet deadlines and customer demands, consolidating an image of excellence. These practices also promote workplace safety, preventing accidents that could compromise employee integrity and negatively impact the company's reputation. By optimizing asset performance, organizations can quickly adapt to market changes and technological innovations, remaining competitive. Moreover, companies that invest in maintenance demonstrate a commitment to sustainability by extending the useful life of their resources, reinforcing a positive image to customers and investors, and strengthening their position in the market. This paper investigates the application of Lean philosophy in the continuous improvement of the production process of a cigarette factory in Portugal. Using a case study, the research examines the implementation of Total Productive Maintenance (TPM) and Autonomous Maintenance practices, focusing on optimizing production processes and reducing waste. The study presents an analysis of performance indicators, such as OEE and Uptime, before and after the implementation of Lean practices. The results show significant improvements in operational efficiency, which increased from 88.08% to 96.30%, product quality, and a reduction in unplanned stoppages from 8.55% to 2.49%. Additionally, the limitations and challenges faced during the implementation process are discussed, such as the need for intensive training and cultural change among operators. This study contributes to the literature, by highlighting the effectiveness of Lean practices in the tobacco industry, proposing a path for continuous improvement and operational excellence.
Description
Dissertação para obtenção do grau de Mestre em Engenharia e Gestão Industrial
Keywords
Filosofia lean Manutenção autónoma Melhoria contínua Total Productive Maintenance Overall Equipment Effectiveness Lean philosophy Autonomous maintenance Continuous improvement
Citation
LOBO, Amanda de Freitas – Aplicação da filosofia Lean na melhoria contínua do processo produtivo do tabaco. Lisboa: Instituto Superior de Engenharia de Lisboa. 2024. Dissertação de Mestrado.