LEAN MANUFACTURING: estudo de caso da implementação de dispositivo Poka Yoke automático em máquina de corte industrial

Abstract

The present case study aims to present how the implementation of an automatic Poka Yoke device in an industrial cutting machine, in the extrusion process, reduced the process variability and waste generated by problems of length outside the specified. Such approach is necessary to solve the problem of high rates of complaints generated by customers receivement of defective parts, and also by the excess of repetitive human activities that cause errors in the process. This study was developed in an automobile industry located in Varginha - MG, whose production process is the extrusion of profiles, which go through the cutting process at the end of the production line. Were realized researches on articles, books and scientific magazines, as well as tools such as Cause and Effect diagram, Statistical Process Control (CEP) and Lean Manufacturing. The final results indicated that there was a reduction in the identified waste and in the variability of the process, as well as an increase in the machine's capacity and the quality of the final products. Such results generated satisfactory effects in the economic, social and environmental spheres, since there was an increase in the profit margin, reduction of non-conforming parts for disposal, elimination of repetitive human work and reliability increase of the company.