Melhoria do processo de fabricação de engrenagens movidas aplicadas ao sistema de partida de motocicletas: um estudo de caso

Abstract

With the globalization of commerce, there's an increasing presence of manufactured products from the Asian market within Brazil. With strong competition and increasingly competitive prices, it is necessary for Brazilian companies to reinvent their operating principles in pursuit of better results. In the metallurgical scenario, this need is no different. It is imperative that production processes become increasingly lean and with the lowest possible reject rate. Quality tools have enormous power in assisting problem resolution. They should be applied to optimize the production process, point out failures and indicate direction in decision making. In this study, the MASP methodology was used and quality tools were applied in a case study within a metallurgical factory to identify improvement points within the process and optimize the manufacturing process of the starter gear used in assisting the electric start of 150 cc motorcycles. The work methodology consists of mapping the entire manufacturing line of the model using the KPI indicators to evaluate productivity, quality, safety, cost, and delivery, applying the GUT decision matrix to point out and guide decision-making, using the Ishikawa diagram according to the 6M's, and applying the brainstorming tool to propose solutions. Three solutions were proposed and after conducting tests, the problem was resolved. As a result, the processing of parts with material failure problems in bore and hub diameters was eliminated. There were also additional gains with process improvements made during the tests of the proposals.