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Melhorias na gestão do estoque

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Promover condições para otimizar a Gestão de Estoque de Embalagens da PB09 através da implantação dos conceitos do Sistema 5S, Kanban e método FIFO.
Organização do ambiente de trabalho, proporcionando qualidade de vida, qualidade de serviço, qualidade dos materiais, qualidade de movimentação e facilidade na implantação de outros programas de melhoria.

Estabelecer Equilíbrio no Nível de Estoque, ao definir políticas de estoque considerando variabilidade da demanda, capacidade de estoque, tempo de entrega, estoque de segurança e custos do estoque.

Published in: Engineering
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Melhorias na gestão do estoque

  1. 1. 1 Melhorias na Gestão do Estoque de Embalagens da Fábrica PB09 Adriano Saito Planejamento Industrial Julho de 2014
  2. 2. 2 Agenda: • Apresentação • Projeto de Estágio • Conclusão
  3. 3. 3 Estagiário: Adriano Saito da Silva Graduação: Engenharia de Produção Civil – 10º fase Universidade Federal de Santa Catarina Área de atuação: Setor Planejamento Industrial Gestor: Ricardo Bottoli Atividades desenvolvidas durante estágio: eficiência do apontamento de base na entrada da ventosa PB09, melhorias no fluxo de atividades e informações no processo de recebimento de matéria-prima. Apresentação
  4. 4. 4 • Tema: Melhorias na Gestão do Estoque de Embalagens da Fábrica PB09 • Interface com as Áreas: Planejamento Industrial, Polimento PB09, Sistema de Gestão, Matéria-Prima. • Alinhamento de Metas: Estoque PA + MP + Processo (dias de ROL) Projeto de Estágio
  5. 5. 5 Plan DoCheck ACT 1 2 3 Identificação do Problema Análise do Fenômeno Análise do Processo 4 Plano de Ação 5 Executar os Planos de Ação6Controle da Eficácia 7Agir Corretivamente Metodologia PDCA 5
  6. 6. 6 Plan DoCheck Act 6
  7. 7. Plan Do Check Act Identificação do Problema PROBLEMA: Ineficiência na Gestão de Estoque de Embalagens da Fábrica PB09
  8. 8. 8 Análise do Fenômeno Política de Estoque Armazenagem e Organização de materiais Gestão de Estoque de Embalagens Movimentação interna de materiais Plan Do Check Act
  9. 9. 9 Plan Do Check Act Armazenagem e Organização de materiais
  10. 10. 10Plan Do Check Act Armazenagem e Organização de materiais
  11. 11. 11Plan Do Check Act Armazenagem e Organização de materiais
  12. 12. 12Plan Do Check Act Armazenagem e Organização de materiais
  13. 13. 13Plan Do Check Act Armazenagem e Organização de materiais
  14. 14. 14 Movimentação interna de materiais Plan Do Check Act A MÉDIA DA CRONOMETRAGEM 2 FOI APROXIMADAMENTE 3 VEZES DA CRONOMETRAGEM 1 Material com localização fixa Material sem localização fixa
  15. 15. 15Plan Do Check Act Política de Estoque “O termo Política de Estoque consiste em normas sobre o que comprar e o que produzir, quando comprar e produzir, e em quais quantidades” Bowersox & Closs (1997). 0 10,000 20,000 30,000 40,000 50,000 60,000 Nível de Estoque - Embalagem 60x60 MP RET Quantidade Política de Estoque indefinida! - Necessidade de estabelecer os seguintes parâmetros: Capacidade do Estoque; Estoque de Segurança; Estoque Médio; Estoque Máximo; Ponto de Pedido; Giro de Estoque; Cobertura de Estoque.
  16. 16. 16 Análise do Processo - Ishikawa Plan Do Check Act
  17. 17. 17 Promover condições para otimizar a Gestão de Estoque de Embalagens da PB09 através da implantação dos conceitos do Sistema 5S, Kanban e método FIFO. Objetivo - Organização do ambiente de trabalho, proporcionando qualidade de vida, qualidade de serviço, qualidade dos materiais, qualidade de movimentação e facilidade na implantação de outros programas de melhoria. - Estabelecer Equilíbrio no Nível de Estoque, ao definir políticas de estoque considerando variabilidade da demanda, capacidade de estoque, tempo de entrega, estoque de segurança e custos do estoque. Plan Do Check Act
  18. 18. 18 Plano de Ação Plan Do Check Act 3. Políticas de Estoque 2. Método FIFO 4. Sistema Kanban 5. Indicadores de Desempenho 1. Sistema 5S
  19. 19. 19 Plan DoCheck Act Plan Do Check Act
  20. 20. 20 Programa 5S É uma filosofia de trabalho que busca promover a disciplina na organização através da consciência e responsabilidade de todos, de forma a tornar o ambiente de trabalho agradável, seguro e produtivo. Plan Do Check Act
  21. 21. 21Plan Do Check Act 1. Sistema 5S • 1º Senso: Seiri – Utilização: - Descartado os insumos danificados e sem possibilidade de recuperação, destinando-os a reciclagem ou devolução. - Classificação ABC dos itens: Classe A  ALTO consumo. Classe B  MÉDIO consumo. Classe C  BAIXO consumo. 0.000% 20.000% 40.000% 60.000% 80.000% 100.000% 120.000% 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 CLASSIFICACAO ABC - EMBALAGENS - MARCO/2014 73% do consumo de embalagens concentra-se em 27% dos itens.
  22. 22. 22 1. Sistema 5S • 2º Senso: Seiton – Organização: - Planejamento do layout, Demarcação da área, Identificação dos itens. Plan Do Check Act
  23. 23. 23 1. Sistema 5S • 3º Senso: Seiso – Limpeza: - Coordenador geral responsável pela limpeza e manutenção periódica. • 4º Senso: Seiketsu – Saúde: - Manter as condições de limpeza e higiene adotadas no Senso anterior. - Facilitar a comunicação visual: melhorar iluminacão do local, Identificação FIFO. • 5º Senso: Shitsuke – Autodisciplina: - Motivar os colaboradores a criacão do hábito de manter a ordem. - Orientar todos os envolvidos para manutenção das melhorias promovidas e padronização das atividades. - Participacão de todos no processo a sentirem-se envolvidos. Convite a reuniões, recebimento de propostas de melhorias para o ambiente de trabalho e constante estímulo dos resultados. Plan Do Check Act
  24. 24. 24 Método FIFO (First in- First out) • Primeiro a entrar é o primeiro a sair. Plan Do Check Act
  25. 25. 25 2. FIFO Plan Do Check Act
  26. 26. 26 2. FIFO Plan Do Check Act
  27. 27. 27 3. Política de Estoque • Embalagem 60x60 MP RET: • Lead Time Fornecedores = 1 dia • Consumo Médio/dia = 7.578 un • Consumo Máximo/dia = 12.000 • Capacidade Estoque = 62.400 un • Estoque Segurança = 12.000 un • Ponto de Pedido = 24.000 un • Estoque Máximo = 42.400 un • Estoque Médio = 19.500 un Plan Do Check Act
  28. 28. 28 Sistema Kanban Kanban: é um dispositivo sinalizador que autoriza e dá instruções para a produção ou para retirada de itens no estoque em um sistema puxado. Plan Do Check Act
  29. 29. 29 4. Cálculo Planilha Kanban Eletrônico Plan Do Check Act
  30. 30. 30 Plan DoCheck Act Plan Do Check Act
  31. 31. 31 Indicadores de Desempenho • Utilização da Capacidade de Estocagem (Storage Utilization): • % Estoque Parado ( por mais de 1 mês) : Plan Do Check Act
  32. 32. 32 Indicadores de Desempenho •Giro de Estoque: •Cobertura de Estoque: Plan Do Check Act
  33. 33. 33 Indicadores de Desempenho • Nível de Estoque x Política de Estoque: Plan Do Check Act
  34. 34. 34 Checagem Visual da Situação Atual Plan Do Check Act
  35. 35. 35 Checagem Visual da Situação Atual Plan Do Check Act
  36. 36. 36 Checagem Visual da Situação Atual Plan Do Check Act
  37. 37. 37 Checagem Visual da Situação Atual Plan Do Check Act
  38. 38. 38 Checagem Visual da Situação Atual Plan Do Check Act
  39. 39. 39 Checagem Plano de Ação Plan Do Check Act Concluídas 89% Em andamento 11%
  40. 40. 40 Plan DoCheck Act Plan Do Check Act
  41. 41. 41 Plano de Ação – Próximas Etapas • Treinamento FIFO aos operadores do Setor de Matéria-Prima que não puderam comparecer no primeiro treinamento. • Implantação do Sistema de Identificação FIFO no estoque de embalagens. (Em andamento) • Reestruturação dos modelos de pallets (Em andamento) dos fardos de caixa de papelão Jorge • Definir procedimento padrão para devolução de materiais (Em andamento) Jorge • Promover Kanban para alguns itens de baixo consumo (Classificação C). Plan Do Check Act
  42. 42. 42 Dificuldades de Estágio e Projeto: “Dependência de vários setores e pessoas para executar as ações necessárias.” “Redução dos desperdícios e dos níveis do estoque de embalagens, além de melhores condições de trabalho, objetivando qualidade no processo e diminuição de custos. ” Perspectivas quanto ao Estágio e Projeto: Conclusão
  43. 43. Obrigado!

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