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Estudo e desenvolvimento de sistema para a rastreabilidade de peças e máquinas
| Name: | Description: | Size: | Format: | |
|---|---|---|---|---|
| 4.04 MB | Adobe PDF |
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Abstract(s)
O relatório apresenta o estudo e desenvolvimento de um sistema de rastreabilidade aplicado à empresa HRV Process Solutions. Inserida no setor da indústria metalomecânica, dedicada ao desenvolvimento e fabrico de equipamentos por encomenda, a empresa caracteriza-se por uma produção com elevada variedade de peças e baixos volumes, fabricadas e assembladas numa etapa final de montagem. Este tipo de produção, marcado pela complexidade e variabilidade, dificulta a gestão e o controlo, originando falhas na rastreabilidade ao longo de todo o processo.
Neste contexto, o trabalho iniciou-se com um diagnóstico aos fluxos documentais e físicos, complementado por uma simulação de retirada de produto, com o objetivo de identificar lacunas e necessidades a colmatar no sistema a desenvolver. O diagnóstico revelou falhas significativas na rastreabilidade de matérias-primas e componentes, ausência de registo de lotes e de sistema FIFO, bem como ineficiências na movimentação de peças entre secções, traduzindo-se em perdas de componentes, erros de montagem e retrabalho não contabilizado.
Para responder a estes desafios, foi concebido um sistema assente em códigos QR, integrados no software GestPro já existente, associado ao conceito de “Volume”: conjuntos de peças de um equipamento ou obra passaram a ser organizados em volumes, cada um identificado por etiqueta e associado a localizações específicas na fábrica, com registo e atualização em tempo real. O sistema foi testado em duas fases: numa primeira implementação, com etiquetas simples acompanhadas por desenhos 2D, e numa segunda, com a introdução de códigos QR que permitiram comunicação direta com o sistema e maior rigor no acompanhamento físico dos volumes.
A análise dos pedidos de produção acompanhados demonstrou a eficácia do sistema, embora tenham sido identificadas oportunidades de melhoria, como o registo histórico das localizações, a integração automática da informação nas guias de transporte, a criação de volumes também no torneamento, a utilização de etiquetas metálicas em determinados casos e a implementação de FIFO com registo de lotes de matérias-primas. Adicionalmente, o sistema possibilitou contabilizar, pela primeira vez, o retrabalho: 527 horas em quatro meses (cerca de 5% do total de produção), sobretudo devido a erros no desenvolvimento de peças e ao desaparecimento de componentes, confirmando a relevância de um sistema de rastreabilidade completo.
Em síntese, o sistema desenvolvido mostrou-se funcional e eficiente, permitindo maior organização e redução de desperdícios. Apesar de carecer de otimizações, constitui um avanço relevante na digitalização da HRV, reforçando a sua competitividade e alinhando-se com os princípios da Indústria 4.0.
The report presents the study and development of a traceability system applied to HRV Process Solutions. Operating in the metalworking industry, dedicated to the development and manufacture of customised equipment, the company is characterised by a high variety of parts and low volumes, manufactured and assembled in a final assembly stage. This type of production, marked by complexity and variability, makes management and control difficult, leading to traceability failures throughout the process. In this context, the work began with a diagnosis of document and physical flows, complemented by a product withdrawal simulation, with the aim of identifying gaps and needs to be addressed in the system to be developed. The diagnosis revealed significant flaws in the traceability of raw materials and components, a lack of batch records and a FIFO system, as well as inefficiencies in the movement of parts between sections, resulting in component losses, assembly errors and unaccounted rework. To respond to these challenges, a system based on QR codes was designed, integrated into the existing GestPro software, associated with the concept of ‘Volume’: sets of equipment or work pieces were organised into volumes, each identified by a label and associated with specific locations in the factory, with real-time recording and updating. The system was tested in two phases: in a first implementation, with simple labels accompanied by 2D drawings, and in a second, with the introduction of QR codes that allowed direct communication with the system and greater accuracy in the physical monitoring of volumes. Analysis of the production orders tracked demonstrated the effectiveness of the system, although opportunities for improvement were identified, such as historical location records, automatic integration of information into transport guides, the creation of volumes also in turning, the use of metal labels in certain cases, and the implementation of FIFO with raw material batch records. In addition, the system made it possible to account for rework for the first time: 527 hours in four months (about 5% of total production), mainly due to errors in the development of parts and the disappearance of components, confirming the relevance of a complete traceability system. In summary, the developed system proved to be functional and efficient, allowing for greater organisation and waste reduction. Although it needs optimisation, it constitutes a significant advance in the digitisation of HRV, reinforcing its competitiveness and aligning it with the principles of Industry 4.0.
The report presents the study and development of a traceability system applied to HRV Process Solutions. Operating in the metalworking industry, dedicated to the development and manufacture of customised equipment, the company is characterised by a high variety of parts and low volumes, manufactured and assembled in a final assembly stage. This type of production, marked by complexity and variability, makes management and control difficult, leading to traceability failures throughout the process. In this context, the work began with a diagnosis of document and physical flows, complemented by a product withdrawal simulation, with the aim of identifying gaps and needs to be addressed in the system to be developed. The diagnosis revealed significant flaws in the traceability of raw materials and components, a lack of batch records and a FIFO system, as well as inefficiencies in the movement of parts between sections, resulting in component losses, assembly errors and unaccounted rework. To respond to these challenges, a system based on QR codes was designed, integrated into the existing GestPro software, associated with the concept of ‘Volume’: sets of equipment or work pieces were organised into volumes, each identified by a label and associated with specific locations in the factory, with real-time recording and updating. The system was tested in two phases: in a first implementation, with simple labels accompanied by 2D drawings, and in a second, with the introduction of QR codes that allowed direct communication with the system and greater accuracy in the physical monitoring of volumes. Analysis of the production orders tracked demonstrated the effectiveness of the system, although opportunities for improvement were identified, such as historical location records, automatic integration of information into transport guides, the creation of volumes also in turning, the use of metal labels in certain cases, and the implementation of FIFO with raw material batch records. In addition, the system made it possible to account for rework for the first time: 527 hours in four months (about 5% of total production), mainly due to errors in the development of parts and the disappearance of components, confirming the relevance of a complete traceability system. In summary, the developed system proved to be functional and efficient, allowing for greater organisation and waste reduction. Although it needs optimisation, it constitutes a significant advance in the digitisation of HRV, reinforcing its competitiveness and aligning it with the principles of Industry 4.0.
Description
Keywords
Rastreabilidade Indústria metalomecânica Engineer-to-Order Códigos QR Retrabalho