Aumento da eficiência global dos equipamentos (OEE) de uma linha de envase de maquiagem de uma indústria de cosméticos
Data
2020-10-16
Autores
Bueno, Simone Rodrigues 
Orientadores
Concha, Viktor Oswaldo Cárdenas
Tipo
Trabalho de conclusão de curso
Título da Revista
ISSN da Revista
Título de Volume
Resumo
Num contexto de mudanças constantes e competitividade acirrada entre as indústrias
manufatureiras do mundo todo, só sobrevivem as empresas capazes de entregar
produtos de qualidade com rapidez, qualidade e baixo custo por meio de uma
produção eficiente e enxuta. Assim, é necessário identificar e eliminar perdas
produtivas tais como quebras, paradas para ajustes, velocidade reduzida, retrabalho,
entre outras. O conceito de manutenção produtiva total (TPM), lançado por Nakajima
nos anos 80 como meio de melhoria da produtividade das linhas, fornece uma métrica
quantitativa chamada eficiência geral do equipamento, ou Overwall Equipment
Effectiveness (OEE), capaz de medir perdas de disponibilidade dos equipamentos,
desempenho e qualidade da produção. Por este motivo, o OEE se faz especialmente
importante e amplamente utilizado como Key Performance Indicator (KPI) para
mensurar melhorias realizadas nos equipamentos. Em vista disso, o presente trabalho
objetivou o aumento de produtividade de uma linha de envase de maquiagem de uma
indústria de cosméticos em um cenário de aumento de demanda significativo e
necessidade de redução de custos. Ele foi realizado utilizando a metodologia DMAIC
(Define, Measure, Analyze, Improve, Control) do Six sigma, uma das metodologias
mais utilizadas para melhoria de processos. O objetivo principal foi o aumento da
eficiência global do equipamento (OEE) da linha de produção de 66,1% para 70% por
meio da redução das principais perdas da linha, que são: ajustes, set-up, tempo de
partida/desligamento e changeover. Os resultados reportados foram um OEE de
75,2%, portanto acima da meta, com a redução das principais perdas citadas em 39%
quando comparado com a % dessas perdas no início do projeto, o que sugere o
sucesso da aplicação da metodologia DMAIC e do trabalho como um todo.
In a context of constant changes and fierce competitiveness among manufacturing industries worldwide, only companies capable of delivering quality products with speed, quality and low cost through efficient and lean production survive. For that, it is necessary identify and eliminate productive losses such as breaks, stops for adjustments, reduced speed, rework, among others. The concept of Total Productive Maintenance (TPM), launched by Nakajima in the 1980s as a way of improving the productivity of the lines, provided a quantitative metric called Overall Equipment Effectiveness (OEE), able to measure losses of equipment availability, performance and production quality. For that reason, the OEE is especially important and widely used as a Key Performance Indicator (KPI) to measure improvements made in equipment. In view of this, the present work came up with the need to increase the productivity of a make-up packaging line of a cosmetics industry in a scenario of significant demand increase and the need to reduce costs. It was accomplished using the DMAIC methodology (Define, Measure, Analyze, Improve and Control) from Six sigma, one of the most used methodologies for process improvement. The main objective was to increase the Overall Equipment Efficiency (OEE) of the production line from 66.1% to 70% by reducing the main losses of the line, which are: adjustments, set-up, start/stop time and changeover. The final result achieved was an OEE of 75.2%, therefore above the target, with the reduction of the main losses mentioned by 39% in relation to the % of these losses at the beginning of the project, which suggests the successful application of DMAIC, SMED and ECRS methodologies, as well as the work as a whole.
In a context of constant changes and fierce competitiveness among manufacturing industries worldwide, only companies capable of delivering quality products with speed, quality and low cost through efficient and lean production survive. For that, it is necessary identify and eliminate productive losses such as breaks, stops for adjustments, reduced speed, rework, among others. The concept of Total Productive Maintenance (TPM), launched by Nakajima in the 1980s as a way of improving the productivity of the lines, provided a quantitative metric called Overall Equipment Effectiveness (OEE), able to measure losses of equipment availability, performance and production quality. For that reason, the OEE is especially important and widely used as a Key Performance Indicator (KPI) to measure improvements made in equipment. In view of this, the present work came up with the need to increase the productivity of a make-up packaging line of a cosmetics industry in a scenario of significant demand increase and the need to reduce costs. It was accomplished using the DMAIC methodology (Define, Measure, Analyze, Improve and Control) from Six sigma, one of the most used methodologies for process improvement. The main objective was to increase the Overall Equipment Efficiency (OEE) of the production line from 66.1% to 70% by reducing the main losses of the line, which are: adjustments, set-up, start/stop time and changeover. The final result achieved was an OEE of 75.2%, therefore above the target, with the reduction of the main losses mentioned by 39% in relation to the % of these losses at the beginning of the project, which suggests the successful application of DMAIC, SMED and ECRS methodologies, as well as the work as a whole.