Aplicação da metodologia DMAIC para redução do tempo de setup de usinagem em corpos de bombas agrícolas

Abstract

This study aims to analyze, propose and implement improvements to reduce the machining setup time of two products from an agricultural machinery company using the DMAIC (Define, Measure, Analyze, Improve, Control) method. Setup refers to the time between the completion of a previous manufacturing process and the start of production of another product, that is, it is the period in which the equipment is idle. In the machining process, setup consists of the following steps: preparation of measuring instruments and calibrators, preparation of machining tools, supply of raw material, removal of the machining device from the previous part, fixing the device from the product to be machined, start of the machining program, and finally, the output of the first finished part. DMAIC is a Six Sigma tool widely used for product and process improvement. The method is divided into five steps, where other methods and auxiliary tools are used to conduct the study. With a focus on reducing setup time and standardizing procedures, the results showed that, after implementing the improvements, the average setup time was reduced by up to 72%, allowing better use of production capacity and reducing manufacturing costs, which contributes to the company's competitiveness. With this result, it is concluded that the use of the DMAIC method coupled with setup optimization techniques is a great option for companies seeking to reduce costs in machining processes.