Simulação e otimização de uma linha de manufatura em fase de projeto

Abstract

Computational simulation together with optimization is an important tool in the development of new projects, as the implantation of a new manufacture line. Simulation can be used in the most varied phases of a new line development, however is in the project phase where the most important decisions are taken. Questions as: How many operators are necessary? Which is the regimen of work? Which is the necessary area? Which is the productivity of the line? Are essential for cost formation of a new line and the precision of these numbers can take the new line to the success or failure. The present study approached the application of these techniques as a planning aid tool in an auto parts factory, to verify the efficiency of the traditional method used by the company where no advanced tool as the simulation is used. The next chapters presented the methodology of these two techniques. Amongst them we can detach the process mapping that beyond of being a basic tool for a good model performance, assisted in the understanding of the process flow of the new line, allowing the correction of errors that could lead the analysis to failure. The ProModel® simulation package, that includes an optimization software based on Genetic Algorithms, the SimRunner®, has been choose. It can be concluded that the results reached through the simulation had been significantly different from the ones reached by the traditional company methodology, mainly in two aspects: labor was reduced in 45% and the productivity of the line was 4% above of the foreseen one. These results had brought some benefits to the company like a new cost formation that will make possible a reduction on manufactured products prices and also making the new line more competitive. Another benefit of these tools for the company is the project graphical visualization in the static and dynamic form, what beyond enriching, facilitates the analysis with data and more precise graphs.