Estudo de tempos para otimizar o processo produtivo: análise e revisão de roteiros de fabricação de uma linha de montagem de ventiladores

Abstract

The search for operational efficiency in production systems is essential for competitiveness and sustainability in the household appliances market. Optimizing the production process and reducing costs are crucial goals, and one way to achieve them is through continuous improvement tools. The case study in question aims to analyze and review the manufacturing routes of a fan assembly line in a home appliance industry, located in the interior of the state of Rio de Janeiro. The case study begins with a mixed methods research approach, combining qualitative and quantitative elements to gain a complete understanding of the production process. This involves the collection, analysis and synthesis of data from previous studies, as well as bibliographical research on lean production and Lean Manufacturing, in order to support the study. Fan manufacturing routes are thoroughly analyzed through a chronoanalysis that allows cycle times, waiting times and bottlenecks to be identified, which provide valuable insights for optimizing production capacity. The new production line layout allows operators to easily access all stations without traveling long distances with a more organized, safe and efficient work environment. One employee on the assembly line was relocated and the other assigned to position C, responsible for packaging the product. Based on the Lean Manufacturing tool, the production process was mapped and time analysis was carried out, resulting in a gain of 78.08 seconds in script time. Station A had a total assembly time of 138.42 seconds, now it is 104.17 seconds. Station B had 82.57 seconds, now operates at 64.10 seconds. And station C, previously with 52.28 seconds, now performs the task in 26.90 seconds. The Yamazumi chart reveals what is value-added and what is not value-added in order to improve productivity. Eliminating wasteful waiting is one of the main focuses of the study. Furthermore, processing waste is identified and eliminated, which leads to the suppression of operations that do not add value to the assembly process, such as: Removing plastic bags during assembly, positioning the motor and column in another cradle, attaching an energy label, data and attention to the column, clean the device, test the ejector button and position shims. The study demonstrates how the application of Lean Manufacturing principles, time analysis, layout restructuring and waste elimination can result in substantial improvements in a fan assembly line.