Publicação
Estudo de tempos e métodos para identificação de desperdícios e gargalos numa linha de reparação de endoscópios
| Resumo: | The Olympus Medical Products Portugal (OMPP) faced significant challenges in their endoscope repair processes, characterized by various inefficiencies that adversely affected the company's performance and resulted in substantial financial costs due to the lack of process optimization.The primary objective of this dissertation was to reduce inefficiencies in the endoscope repair processes. To achieve this goal, parameters in the Main Assembly cell were optimized, and non-value-added tasks were eliminated after identification, aiming to eliminate overprocessing. Additionally, the cell layout was reconfigured to enhance efficiency. Other objectives included reducing Work in Progress (WIP), improving process output, and eliminating intermediate stocks and potential constraints.Given the complexity of the issues addressed in this study and the limited timeframe for cell optimization, the PDCA (Plan-Do-Check-Act) cycle was chosen as the primary approach for problem structuring. Throughout the dissertation, various tables with process time records were developed, playing an essential role in the organization, measurement, and more precise monitoring of each repair process. An Ishikawa diagram was also developed, highlighting the main causes of waste and inefficiencies in the repair processes.The implementation of strategies during the “Execution” phase resulted in significant reductions in cell inefficiencies. The workspace reconfiguration reduced the time required to locate work from 8 minutes initially measured to 1.5 minutes after the layout change, and from 3.5 minutes to 30 seconds for each work change on the benches. The strategy of locating the parts that compose the work in MA1 eliminated unnecessary technician movements and reduced the time spent searching for work, resulting in an annual saving of €27,506.33 in each repair line of the Main Assembly cell. The elimination of intermediate stocks and the reduction in work change time along the repair lines resulted in a significant reduction in rework and an annual saving of €30,380.11 per repair line.The implementation of the 5S methodology at the workstations, by itself, did not significantly increase efficiency, suggesting the need for future studies. Regarding the strategy to reduce inventory waste, it was not possible to implement it within the timeframe of this project. However, this strategy appears to be very promising, with an estimated annual saving of €50,000. |
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| Autores principais: | Valuca, Eduardo Bambi |
| Assunto: | Methods Time Waste PDCA Timing Métodos Tempos Desperdícios PDCA Cronometragem |
| Ano: | 2024 |
| País: | Portugal |
| Tipo de documento: | dissertação de mestrado |
| Tipo de acesso: | acesso aberto |
| Instituição associada: | Universidade de Coimbra |
| Idioma: | português |
| Origem: | Estudo Geral - Universidade de Coimbra |
| Resumo: | The Olympus Medical Products Portugal (OMPP) faced significant challenges in their endoscope repair processes, characterized by various inefficiencies that adversely affected the company's performance and resulted in substantial financial costs due to the lack of process optimization.The primary objective of this dissertation was to reduce inefficiencies in the endoscope repair processes. To achieve this goal, parameters in the Main Assembly cell were optimized, and non-value-added tasks were eliminated after identification, aiming to eliminate overprocessing. Additionally, the cell layout was reconfigured to enhance efficiency. Other objectives included reducing Work in Progress (WIP), improving process output, and eliminating intermediate stocks and potential constraints.Given the complexity of the issues addressed in this study and the limited timeframe for cell optimization, the PDCA (Plan-Do-Check-Act) cycle was chosen as the primary approach for problem structuring. Throughout the dissertation, various tables with process time records were developed, playing an essential role in the organization, measurement, and more precise monitoring of each repair process. An Ishikawa diagram was also developed, highlighting the main causes of waste and inefficiencies in the repair processes.The implementation of strategies during the “Execution” phase resulted in significant reductions in cell inefficiencies. The workspace reconfiguration reduced the time required to locate work from 8 minutes initially measured to 1.5 minutes after the layout change, and from 3.5 minutes to 30 seconds for each work change on the benches. The strategy of locating the parts that compose the work in MA1 eliminated unnecessary technician movements and reduced the time spent searching for work, resulting in an annual saving of €27,506.33 in each repair line of the Main Assembly cell. The elimination of intermediate stocks and the reduction in work change time along the repair lines resulted in a significant reduction in rework and an annual saving of €30,380.11 per repair line.The implementation of the 5S methodology at the workstations, by itself, did not significantly increase efficiency, suggesting the need for future studies. Regarding the strategy to reduce inventory waste, it was not possible to implement it within the timeframe of this project. However, this strategy appears to be very promising, with an estimated annual saving of €50,000. |
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