Embed Size (px)
Citation preview
Utilization of tool Value Stream Mapping (VSM) for improvement of welded assembly manufacturing process 15/07/2013 UNIJUÍ – RS - BRASIL PROF DR GILGUIMARAES
UNIJUÍ – RS - BRASIL Guimarães, Gil Eduardo
Doctor of Science in Materials Engineering Especialist in Industrial Engineering
Muller, Maiquel supervisor of productive cell of this study Student of Mechanical Engineering
Taffarel, Lucas Lash, Marcelo Bechert,Tobias
Students of Mechanical Engineering
15/07/2013 UNIJUÍ – RS - BRASIL 2
Introduction
Due to the globalization of markets and their consequent expansion, more and more companies seek to increase the efficiency of their processes.
Recently the philosophy of lean manufacturing has been consolidated in the industry, spreading the culture of waste elimination.
15/07/2013 UNIJUÍ – RS - BRASIL 3
This systemic thinking focuses on value-creating processes, from raw material to finished product, involving all productive agents, from the most primitive supplier to the end customer.
In addition there is an extensive development of people and not only of processes and / or products.
15/07/2013 UNIJUÍ – RS - BRASIL 4
The present work is an example of the actions that have been taken within the company in order to identify opportunities to improve processes and increase productivity.
These actions were motivated by customer requirements and by the action of competition
15/07/2013 UNIJUÍ – RS - BRASIL 5
Value Stream Mapping (VSM)
The mapping process is a management tool that aims to help improve existing processes or deploy a new structure oriented to processes.
The mapping also helps the company to clearly see the strengths and weaknesses, as well as being a great way to improve understanding of the processes and increase business performance.
15/07/2013 UNIJUÍ – RS - BRASIL 6
Ten steps to map and model a process Identify the process objectives Identify the process outputs Identify the customers of the process Identify the inputs and process components Identify the suppliers of the process Determine the boundaries of the process Document the current process Identify needed improvements of the process Consensus on the improvements to be applied to the
process Document the revised process
15/07/2013 UNIJUÍ – RS - BRASIL 7
Current state map
Expedição
Corte Usinagem EstamparPosto de solda 1
Posto de solda 2
Acabamento Mandrilar Pintar Montar
OP A OP B OP C OP D OP D OP E OP F OP G OP H
PPCP
Cliente John Deere
ComercialComprasFornecedor
MP
E EE E EE EE E E
Produção em lotes
15/07/2013 UNIJUÍ – RS - BRASIL 8
Current state map
Posto de solda 1
Posto de solda 2
Acabamento
OP D 100un OP D 100un OP E
EE E E
2:45:00 10:10:000:01:45 0:01:21 0:03:30
15/07/2013 UNIJUÍ – RS - BRASIL 9
Current state lay-out
15/07/2013 UNIJUÍ – RS - BRASIL 10
Analysis of the Current State MapActivities AV NAV
Posto de solda 1 0:01:45
Estoque 2:45:00
Posto de solda 2 0:01:21
Estoque 10:10:00
Acabamento 0:03:30
Subtotal 0:06:36 12:55:00
Total 13:01:36
15/07/2013 UNIJUÍ – RS - BRASIL 11
Analysis of the Current State Map
15/07/2013 UNIJUÍ – RS - BRASIL 12
Needed improvements of the process
Stock high on the work station of welding: All parts are stocked in the sector, which increases the need for physical space and makes it difficult inventory control.
Standby time high in welding and finishing; the production is done by batch, so parts needed to wait for the entire batch to be ready to proceed to the next process.
15/07/2013 UNIJUÍ – RS - BRASIL 13
Disorganization of welding devices; the devices are arranged in a table, without identification and appropriate locations.
Layout of the work station of welding is inappropriate; the sector is not functional because the welder should get the parts at distances up to 3 meters, the input and output parts do not have a location set.
15/07/2013 UNIJUÍ – RS - BRASIL 14
Suggested improvements 1st - Reduced inventory of components in gas welding:
All the inventory will be transferred to the warehouse, where there is an appropriate place in the industry and the quantity of welding parts in the work station will only be for the production of a day.
2nd - Develop continuous flow processes for welding and finishing: Create a cell welding and finishing that allows the continuous stream and eliminate stocks between processes.
15/07/2013 UNIJUÍ – RS - BRASIL 15
3rd - Improvements in welding devices and welding processes: Restructure the layout, improve the arrangement of devices and use a anti-spatter spray of welding to decrease the time in the finishing operation.
4th - Definition of the areas in the assembly that should be free of weld spatter: Make a study of the areas where it really necessary to remove weld spatter for the finishing is made only where needed
15/07/2013 UNIJUÍ – RS - BRASIL 16
Future state lay-out
15/07/2013 UNIJUÍ – RS - BRASIL 17
Future state map
Expedição
Corte Usinagem EstamparCélula Pedais
Mandrilar Pintar Montar
OP A OP B OP C OP D,E,F OP G OP H OP I
Cliente John Deere
PPCP
ComprasFornecedor
MP
Comercial
E E EE EE E E
Produção Contínua
15/07/2013 UNIJUÍ – RS - BRASIL 18
Future state map
Célula Pedais
OP D,E,F
E E
0:04:56
15/07/2013 UNIJUÍ – RS - BRASIL 19
Analysis of the Current State Map
Activities Process TC (minutes) Operator %
1 Posto desolda 1 0:01:45 D 100
2 Posto de solda 2 0:01:21 E 100
3 Acabamento 0:01:50 F 100
15/07/2013 UNIJUÍ – RS - BRASIL 20
Analysis of the Current State Map
Activities AV NAV
Célula Pedais 0:04:56
Subtotal 0:04:56 00:00:00
Total 0:04:56
15/07/2013 UNIJUÍ – RS - BRASIL 21
Analysis of the Current State Map
15/07/2013 UNIJUÍ – RS - BRASIL 22
CONCLUSÃO The future state map showed very significant
improvements, such as the elimination of non-value added activities.
It is evident, therefore, that with the application of value stream mapping (VSM) in the process of the company there is a reduction in lead time, more than 13 hours for about 5 minutes, giving the company much more quickness in meeting the demands of your client as well as a better use of its resources, which is crucial in a globalized world in which the company operates.
15/07/2013 UNIJUÍ – RS - BRASIL 23
