Diretrizes para projeto e operação de cadeias de ajuda em Sistemas de Produção Enxuta

Pelizzon, Alexandre; Saurin, Tarcisio Abreu; Marodin, Giuliano Almeida

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Brasil

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Sumário

Original Articles • Gest. Prod. 26 (4) • 2019 • https://doi.org/10.1590/0104-530X1974-19 copiar

Diretrizes para projeto e operação de cadeias de ajuda em Sistemas de Produção Enxuta

Autoria SCIMAGO INSTITUTIONS RANKINGS

Resumo

O sucesso na implantação de muitas das práticas lean depende da existência de uma estabilidade produtiva básica. Por sua vez, um dos meios de se obter estabilidade é através de rotinas padronizadas para a solução das anormalidades, como as das cadeias de ajuda. O objetivo deste trabalho é propor diretrizes para o projeto e operação de cadeias de ajuda, tratando de questões como a definição de quais eventos necessitam do suporte da cadeia e a seleção dos membros que devem ser envolvidos. As diretrizes propostas envolvem sete passos: (i) delimitação e avaliação do local de aplicação; (ii) identificação e classificação das anormalidades; (iii) identificação dos tipos e conteúdos dos dispositivos visuais; (iv) identificação dos agentes envolvidos na cadeia de ajuda; (v) definição da lógica de operação da cadeia de ajuda; (vi) treinamento e capacitação; e (vii) aplicação e avaliação de resultados. Uma aplicação parcial em uma indústria gráfica ilustra o uso das diretrizes, servindo de base para a discussão de seus pontos fortes e fracos.

Palavras-chave:
Cadeia de ajuda; Gestão da rotina; Produção enxuta

Feature	Printer1	Printer 2	Printer 3	Printer 4
Units	10 units	8 units	9 units	4 units
Capacity	400m/min	400m/min	250m/min	500m/min
Substrate	Up to160g/m²	Up to 160g/m²	Up to 600g/m²	Up to 600g/m²
Product	Printed jumbo coil (semi-finished)	Printed jumbo coil (semi-finished)	Case (finished)	Printed jumbo coil (semi-finished)
Automatic controls	Color register, visual inspection, oven temperature, substrate tensioning, ink viscosity, and substrate-feeding device device	Color register, visual inspection, oven temperature, substrate tensioning, ink viscosity, and substrate- feeding device	Color register, visual inspection, oven temperature, substrate tensioning, ink viscosity, embossing, creasing, cutting, substrate accumulator, and substrate-feeding device	Color register, oven temperature, substrate tensioning, and substrate-feeding device

Steps	Involved	Documents used
(i) Scenario delimitation and evaluation of the scenario	Plant managers (6 coordinators and 5 managers)	Assessment questionnaire of compliance between scenario and CSF for implementing the help chain structure
(ii) Identification and classification of abnormalities.	2 process engineering coordinators and 2 process analysts	Abnormality registering system (via SAP ERP)
(iii) Identification of the visual device types and contents	3 production and maintenance managers from the paper and cardboard department, 2 process engineering coordinators, 2 process engineering analysts, 4 graphic technicians (1 per machine), and 1 external consultant (A3 process specialist)	Printing company proprietary guidelines for implementing the lean philosophy in its worldwide subsidiaries; production note forms, quality defects, and downtime; planned production calculation spreadsheet; quality assessment worksheet; internal classification of occupational safety risk levels; and the literature on the problem-solving process, A3, andons, and visual management
(iv) Identification of agents involved in the help chain	3 production and maintenance managers from the paper and cardboard department, 2 process engineering coordinators, 1 maintenance coordinator, and 2 process analysts	Hierarchical structures of the printing and maintenance areas; placement of employees in work shifts; matrices of functional competences and professional history (length of the experience in the function)
(v) Defining the help chain operation logic	3 production and maintenance managers from the paper and cardboard department, 2 process engineering coordinators, 1 maintenance coordinator, 2 process analysts, and 1 maintenance analyst	Documents and products from previous steps; historical records of break and fail reports (BFR); mapping of potential abnormalities; previous time and movement studies of the Maintenance department; and the literature on routine management
(vi) Training the agents involved	3 production and maintenance managers from the paper and cardboard department, 10 process analysts, and operators from all the printing production sectors	All the documents/products resulting from the previous steps and literature on help chain, A3 process, routine management, and visual management
(vii) Application and evaluation of results	3 production and maintenance managers from the paper and cardboard department, 10 process analysts, and operators from all the printing production sectors.	Structures and routines created for the help chain, resulting from the previous steps; production system (OEE and scrap) metrics pre- and post-implementation; and unstructured interviews.

Group (area/sector)	Score Number of events	Overall downtime score	Priority indicator
Operational	14	14	196
Corrective Maintenance	13	11	143
Cylinder engraving	11	12	132
PMR	12	10	120
Managerial	9	13	117
Quality	10	9	90
Development	8	8	64
Support	6	6	36
Preventive Maintenance	5	7	35
Tooling	7	4	28
PPC	4	5	20
OHSE	3	3	9
Pre-press	2	2	4
Washing parts	1	1	1

Universidade Federal de São Carlos Departamento de Engenharia de Produção , Caixa Postal 676 , 13.565-905 São Carlos SP Brazil, Tel.: +55 16 3351 8471 - São Carlos - SP - Brazil
E-mail: gp@dep.ufscar.br

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[1] PMR = Pre Make Ready; PPC = Production Planning and Control; OHSE = Organizational Health, Safety & Environment.