Nivelamento da produção dentro de uma fundição através do sequenciamento de produção e análise do mapeamento do fluxo de valor

Abstract

This study was made to analyze the problem of scheduling and sequencing of production in a foundry. To accomplish this, a Value Stream Mapping was performed aiming to identify improvement points for the whole process, and what actions are necessary to eliminate large wastes in the process and move towards a lean production system. The focus of the work was on the sequencing of the production between the Molding and Finishing operations, and for this a method was used to analyze the scheduling between the days and also the sequencing of the existing orders in each day, aiming the leveling of the production among the Stages of the process, but still obeying the constraints of the other stages of the foundry. Using a genetic algorithm, the potential gains in the implementation of the developed tools were measured. These tools developed showed significant gains in leveling of production by reducing the standard deviation in the machine load programmed between the days in the process steps. In addition, there are gains in day-to-day leveling between the Molding and Finishing steps, reducing fluctuations in casting temperature and the queue size in Finishing operation, reducing the problem of exceed the capacity of the buffer, creation of the intermediate stock, excess of movements, loss of the FIFO and delays in delivery.