Redução de custos da manutenção utilizando a metodologia world class manufacturing: um estudo de caso

Abstract

The day-to-day maintenance planning is full of work routines and flows to follow. It is necessary to follow a methodology to guide and manage the resources. The WCM (WORLD CLASS MANUFACTURING) methodology guides the necessary steps to follow in order to reduce production costs, minimize losses and increase equipment reliability. No pillar of professional maintenance, these steps are key to reducing equipment breakdowns, increasing component life and reducing maintenance costs. Being divided into 7 steps, the first three steps being considered a reactive action, the fourth and fifth a preventive action and the sixth and seventh a proactive action. The case study is a work carried out specifically in step 4 of professional maintenance, where reverse engineering concepts were used to increase the useful life of a critical component for the polyurethane injection process. This work aims to apply in practice a case study to demonstrate the reduction of preventive maintenance costs by applying the WCM methodology, in an appliance company. An equipment was selected by prioritizing costs and through its preventive maintenance plan the component that requires major maintenance repairs was found. Applying the concepts of reverse engineering, the mechanical properties of the component imported from the manufacturer were analyzed, thus finding the appropriate material for application in the process. The material found was DIN 41CrAlMo7 steel known as Nitralloy 135M steel. Not being marketed in Brazil, a selection of materials was carried out to find other material similar to the original. This is how SAE 8550 steel is found, which has alloying elements similar to the original steel. Material that, according to the bibliographical analysis, it is possible to apply the same manufacturing processes and thus achieve the same mechanical properties of the original component. In this way, it was possible to reduce the costs of preventive maintenance of this equipment by R$ 32,064.00 per year, proving to be satisfactory the application of the methodology in the company.