Implementação de um sistema de controle de Wip em uma linha de montagem industrial: uma aplicação do software Plant Simulation

Abstract

In light of the intensifying competition in industry and the mounting customer demands for high-quality products and efficient delivery times, companies are compelled to continuously enhance their processes to meet these expectations. In this context, computer simulation emerges as a potent instrument for implementing improvements in manufacturing processes. This is because it offers a virtual representation of a system with different scenarios, which facilitates informed decision-making regarding the changes or improvements to be made. Consequently, in this study, the Tecnomatix Plant Simulation software was employed to ascertain the optimal size of WIPs for an automotive radio assembly line in the Manaus Industrial District, with due consideration of the Just in Time (JIT) principle of producing only what is necessary and avoiding overproduction. The computer simulation utilized authentic data from the assembly process, obtained through chrono-analysis of the workstations. Following the sizing of the WIPs, a mechanical device was constructed to limit the quantity of products in the WIP. An automatic system was also developed to control FiFo within these buffers using the Arduino Uno microcontroller. The implementation of this system to limit the quantity and maintain the FiFo of the WIP parts was satisfactory, as it was possible to reduce the idle time of the machines in the process by 85%, resulting in an increase in the production capacity of the line from 31 parts per hour to 33 parts per hour, which is equivalent to a 6% increase in the production capacity of the line, bringing a return of R$ 14.090.79 reais per year for the company under study, in addition, it was possible to reduce the rate of defects caused by the hardening of the thermal paste of the products by 37%.