Redução dos custos de transformação no processo de torneamento dos eixos da carcaça 63 a 100 em uma fábrica de motores elétricos no sul do Brasil aplicando a metodologia do Mapeamento de Fluxo de Valor

Abstract

The scientific research in question, was based on a case study, applied in an industry of the metal mechanic branch that operates in the manufacture of electric motors located in the south of Brazil. The study aims to increase the company’s level of competitiveness, reducing the transformation costs in the shaft turning process of frame 63 to 100 through the identification of the optimal work center for the manufacture of each batch of shafts. As a parameter to identify cost reduction, production data from all axes manufactured in 2019 were used. When linking the study with STP tools such as MFV and kaizens, it was found that with the correct application of the tools, it is possible to obtain significant results in eliminating losses, as they are easy to apply and all employees are involved and feel part of the entire organizational system. The case study was carried out using the Value Flow Mapping in the process of turning steel components where it had a high setup and execution time, due to the lack of a well-defined criterion to register in the SAP system the best alternative work center used for the manufacture of the axes and the ideal batch size of each work center. Value Stream Mapping (MFV) is a tool widely applied on the shop floor to quickly identify the inefficiencies inherent in the process and correct them. Its objective is to improve the production flow, reduce costs and consequently obtain increased productivity and profits. With the completion of the work, a reduction of 7% in setup and execution of the process was obtained.