Implementação de Kaizen baseado na criação de um sistema de proteção contra a entrada de objetos metálicos em canhões de extrusoras de tintas em pó

Abstract

The present work proposes the accomplishment of a study that will show how much viable is to create a protection system that detects the entrance of metallic objects in the barrels of the extruders during the powder coat extrusion process. This process is considerably burdened by the high cost of mechanical components wearing out which are in contact with the product during the extrusion process, being the main components, the pins and elements, which are extremely damaged when a metallic object enters the barrels while the extrusion process is in progress. The cost resulting from the constant and necessary replacement of pins and elements impacts directly in the product final price. Carefully analyzing this process it was possible to observe that there are two controllable causes which cause the breaking of these wearing out parts: the first one is the accidental entry of some metallic object that may be occasionally mixed with the inputs used in the manufacture of the coat. The second possibility is probably by improper human action, such as the use of metal tools during the cleaning and maintenance. In any of the occurrences, due to the helical movement inside the barrel, the presence of metallic materials will continue breaking the pins and elements that compose it. It should also be noted that, for each type of coat there is a configuration of pins and elements, which, in turn, can increase the costs in the event of a breakdown. To exemplify, the waste caused in the month of February 2020, there was a break caused by the entry of a metallic foreign body causing the breaking of some pins and elements, accounting a loss of approximately R $ 47,000.00 only in this event. Based on these facts, and based on the Kaizen understandings, it is proposed to conduct a study of the case in order to design a device that is able to detect the presence of metallic objects in the barrels entrance. Such device would contribute to the equipment being turned off upon detection of any foreign body, avoiding or reducing damage to the equipment.