Redução de desperdícios na abordagem do Lean Manufacturing: estudo de caso na fabricação de cabos transpostos na unidade de Itajaí - SC da WEG Motores S/A

Abstract

Currently, companies are constantly looking for product quality, productivity and competitiveness. In this way, with some tools, the Lean Manufacturing assists to improve the quality of products, processes and reduce waste, allowing companies to achieve a competitive advantage against their competitors. In this way, this study have the target to propose improvements in the manufacturing process of transposed cables, to identify the three biggest losses that exist in the manufacturing process, based on the Lean Manufacturing approach. To conduct this study, the rectangular wire-manufacturing department was chosen at the WEG Motors unit in Itajaí-SC. The manufacturing process of the transposed cable is composed of two parallel stacks of enameled rectangular wires and each wire that makes up the cable assumes all possible positions in both stacks, in the cross section of the cable and several times around it. To identify the three biggest losses and propose improvements in the process, data were collected over a six-month period (January to June 2019) through the Overall Efficiency Equipment (OEE). With the stratification of these data, the Lean Manufacturing approach was applied, with assists of some of its tools: kaizen, reduction of setup and 5S. In this context, such tools were fundamental for the elaboration of a plan for the implementation of improvements in the process. After the improvements implemented, there was an average reduction of 41% in the time of adjustment during the process, an average reduction of 41% in the time to recover the transposition failures, an average reduction of 25% in the time to weld the wires and 22% reduction in setup. With the implementation of the proposed improvements, a reduction of 327.88h was obtained in the biggest losses in the manufacturing process of transposed cables, making it is possible to increase the machine time available to the department.