Utilizando o AHP para melhoria de processos de fabricação em TPM em um complexo industrial e portuário

Autores

DOI:

https://doi.org/10.5585/exactaep.2021.16693

Palavras-chave:

TPM, AHP, Melhorias de processo, Ranking, Suape

Resumo

Este trabalho teve como objetivo desenvolver um modelo que classifique os fatores críticos para a melhoria do processo produtivo sob a ótica da Manutenção Produtiva Total (TPM) em seis empresas localizadas na região do Complexo Industrial de Suape. O trabalho classificou-se em pesquisa aplicada, qualitativa e quantitativa, exploratória e descritiva, e estudo de caso. O modelo proposto desenvolvido utilizou o método Analytic Hierarchy Process (AHP) utilizando seis critérios: Breakdown do equipamento, Long Setup, Small Stops, Redução da velocidade, Produção defeituosa, Start-up. Os resultados mostraram que todos os seis critérios foram considerados como fatores críticos de incremento para melhoria do TPM e do tomador de decisão, e os fatores que mais contribuíram foram longos setups e quebra de equipamentos com quase 50%. A contribuição do estudo é desenvolver um modelo que permita a possibilidade de um agrupamento classificatório de fatores críticos para aumentar a melhoria, do ponto de vista do TPM e do tomador de decisão.

Downloads

Não há dados estatísticos.

Biografia do Autor

Fagner José Coutinho de Melo, Universidade Federal de Pernambuco – UFPE

Doutor em Engenharia de Produção

Universidade Federal de Pernambuco – UFPE

Recife, Pernambuco, Brasil.

Juliana Valença Sousa, Universidade Federal de Pernambuco – UFPE

Mestre em Engenharia de Produção
Universidade Federal de Pernambuco – UFPE
Recife, Pernambuco, Brasil.

Joás Tomaz de Aquino, Universidade Federal de Pernambuco – UFPE

Mestre em Administração

Universidade Federal de Pernambuco – UFPE

Recife, Pernambuco, Brasil

Taciana de Barros Jerônimo, Universidade Federal de Pernambuco – UFPE

Doutora em Engenharia de Produção

Universidade Federal de Pernambuco – UFPE

Recife, Pernambuco, Brasil.

Referências

Ahuja, I.P.S., & Khamba, J.S. (2008a). An evaluation of TPM initiatives in Indian industry for enhanced manufacturing performance. International Journal of Quality & Reliability Management, 25(2), 147-172. DOI: https://doi.org/10.1108/02656710810846925

Ahuja, I.P.S., & Khamba, J. S. (2008b). Assessment of contributions of successful TPM initiatives towards competitive manufacturing. Journal of Quality in Maintenance Engineering, 14(4), 356-374. DOI: https://doi.org/10.1108/13552510810909966

Ahuja, I.P.S., & Singh, P. (2012). Application of analytical hierarchy process for justification of TPM implementation in manufacturing organizations. International Journal of Technology, Policy and Management, 12(1), 37-47. DOI: https://doi.org/10.1504/IJTPM.2012.044967

Ahuja, I.P.S., & Singh, P. (2017), Total Productive Maintenance - A Tool for World Class Manufacturing, International Journal of Advanced Production and Industrial Engineering. Special Issue on Operations & Supply Chain Management, pp. 20-23.

Ahuja, I.S., & Singh, P. (2013). Total productive maintenance: a tool for envisaging manufacturing competence. International Journal of Technology, Policy and Management, 13(2), 107-120. DOI: https://doi.org/10.1504/IJTPM.2013.053083

Almeida, A. T.; Cavalcante, C. A. V.; Alencar, M. H.; Ferreira, R. J. P.; De Almeida-Filho, A. T.; & Garcez, T. V. (2015). Multicriteria and multiobjective models for risk, reliability and maintenance decision analysis. New York: Springer. DOI: https://doi.org/10.1007/978-3-319-17969-8

Bataineh, O., Al-Hawari, T., Alshraideh, H., & Dalalah, D. (2019). A sequential TPM-based scheme for improving production effectiveness presented with a case study. Journal of Quality in Maintenance Engineering, 25(1), 144-161. DOI: https://doi.org/10.1108/JQME-07-2017-0045

Bertolini, M., Bevilacqua, M., Braglia, M., & Frosolini, M. (2004). An analytical method for maintenance outsourcing service selection. International Journal of Quality & Reliability Management, 21(7), 772-788. DOI: https://doi.org/10.1108/02656710410549118

Breja, S.K., Banwet, D.K. & Iyer, K.C. (2011). Quality strategy for transformation: a case study. The TQM Journal, 23(1), 5-20. DOI: https://doi.org/10.1108/17542731111097452

Cooper, D. R. & Schindler, P. M. (2013), Business Research Methods, 12th Edition. McGraw-Hill Education.

Díaz-Reza, J.R., García-Alcaraz, J.L. & Martínez-Loya, V. (2019). TPM Literature Review”, in Díaz-Reza, J. R., García-Alcaraz, J.L. and Martínez-Loya, V, Impact Analysis of Total Productive Maintenance Critical Success Factors and Benefits, Springer Nature, Switzerland, pp.23-29

Emrouznejad, A., & Marra, M. (2017). The state of the art development of AHP (1979–2017): A literature review with a social network analysis. International Journal of Production Research, 55(22), 6653-6675. DOI: https://doi.org/10.1080/00207543.2017.1334976

Escobar, M.T., & Moreno-Jimenéz, J.M. (2007). Aggregation of individual preference structures in AHP-group decision making. Group Decision and Negotiation, 16(4), 287-301. DOI: https://doi.org/10.1007/s10726-006-9050-x

Forman, E., & Peniwati, K. (1998). Aggregating individual judgments and priorities with the analytic hierarchy process. European journal of operational research, 108(1), 165-169. DOI: https://doi.org/10.1016/S0377-2217(97)00244-0

Garg, A., & Deshmukh, S.G. (2006). Maintenance management: literature review and directions. Journal of quality in maintenance engineering, 12(3), 205-238. DOI: https://doi.org/10.1108/13552510610685075

Guarda, A. & Felipe, E., (2015). Documento Suape 2015: Retomada necessária. Especiais JC Online. Jornal do Commercio. Recife, 7 July, 2015. Available at: http:// especiais.jconline.ne10.uol.com.br/documento-suape-2015/ (accessed 9 December 2015).

Hair, Jr. J., & Page, M. (2018). The Essentials of Business Research Methods, 13rd Edition. McGraw Hill Education.

HajShirmohammadi, A., & Wedley, W.C. (2004). Maintenance management–an AHP application for centralization/decentralization. Journal of Quality in Maintenance Engineering, 10(1), 16-25. DOI: https://doi.org/10.1108/13552510410526839

Hansen, R. C. (2005). Overall Equipment Effectiveness: a powerful production/maintenance tool for increase profits, Industrial Press Inc., New York.

Huang, C. T., Yeh, T. M., Lin, W. T., & Lee, B. T. (2009). A fuzzy AHP-based performance evaluation model for implementing SPC in the Taiwanese LCD industry. International Journal of Production Research, 47(18), 5163-5183. DOI: https://doi.org/10.1080/00207540801935608

Jain, A., Gupta, R.C., & Soni, S. C. (2014). Analytical Hierarchy Process for Identification of Attributes for TPM Implementation, Voice of Research. 3(3), 41-45.

Jain, A., Singh, H., & Bhatti, R. S. (2018). Identification of key enablers for Total Productive Maintenance (TPM) implementation in Indian SMEs: a graph theoretic approach. Benchmarking: An International Journal, 25(8), 2611-2634. DOI: https://doi.org/10.1108/BIJ-02-2016-0019

Jha, C.K., & Singh, A. (2016). Study of Total Productive Maintenance: A Case Study of OEE Improvement in Automobile Industry, Benefits and Barriers in TPM Implementation. International Journal for Technological Research in Engineering, 3(9), 2400-2406.

Jasiulewicz-Kaczmarek, M. & Saniuk A., (2017). How to Make Maintenance Processes More Efficient Using Lean Tools? in Richard H.M. Goossens (ed.), Advances in Social & Occupational Ergonomics, Proceedings of the AHFE 2017 International Conference on Social & Occupational Ergonomics, Advances in Intelligent Systems and Computing, 605, 9-20.

Jerônimo, T. B., Melo, F. J. C., & Aquino, J. T. (2016). An implementation of the multi-criteria decision model: how managers apprehend the importance of rational decisions. Exacta, São Paulo, 14(2), 319-334.DOI: https://doi.org/10.5585/ExactaEP.v14n2.6409

Kodali, R., & Chandra, S. (2001) Analytical hierarchy process for justification of total productive maintenance. Production Planning & Control: The Management of Operations, 12(7), 695-705. DOI: https://doi.org/10.1080/09537280010024045

Kodali, R., Prasad Mishra, R., & Anand, G. (2009). Justification of world-class maintenance systems using analytic hierarchy constant sum method. Journal of Quality in Maintenance Engineering, 15(1), 47-77. DOI: https://doi.org/10.1108/13552510910943886

Küçük, B. B. & Korkut, D. S. (2016). Investigation of total productive maintenance facilities in forest products industry, example of Inegöl. Kastamonu Üniversitesi Orman Fakültesi Dergisi, 16(2), 401-411. DOI: https://doi.org/10.17475/kastorman.289750

Labib, A.W., O’Connor, R.F., & Williams, G.B. (1998). An effective maintenance system using the analytic hierarchy process. Integrated Manufacturing Systems, 9(2), 87 – 98. DOI: https://doi.org/10.1108/09576069810202005

Labib, A.W., Corte, M.C., & Williams, G.B. (1997). Towards a world class maintenance programme. CIRP International Symposium on Advanced Design and Manufacture in the Global Manufacturing Era. Hong Kong, 1, pp. 82-88.

Madu, C. N. (1994). On the total productivity management of a maintenance float system through AHP applications. International journal of production economics, 34(2), 201-207. DOI: https://doi.org/10.1016/0925-5273(94)90036-1

Manihalla, P. P., Gopal, R. C., Rao, S. T., & Javaraiah, R. M. (2019). A survey on factors affecting total productive maintenance (TPM) in service industries. In AIP Conference Proceedings. 2080(1), 060005. DOI: https://doi.org/10.1063/1.5092940

Moraes, J., & Clemente, A. (2015). Toyota confirms parts warehouse in the Suape Port Complex. Diário de Pernambuco, Recife, 4 May 2015. Available at: http://www.diariodepernambuco.com.br/app/noticia/economia/2015/02/11/internas_economia,560380/toyota-confirma-galpao-de-pecas-no-complexo-portuario-de-suape.shtml (accessed 4 May 2015).

Nakajima, S. (1988). Introduction to TPM – Total Productive Maintenance, Cambridge, MA: Productivity Press.

Netland, T.H. & Sanchez, E. (2014). Effects of a production improvement programme on global quality performance: The case of the Volvo Production System. The TQM journal, 26(2), 188-201. DOI: https://doi.org/10.1108/TQM-03-2012-0023

Pačaiová, H., & Ižaríková, G. (2019). Base Principles and Practices for Implementation of Total Productive Maintenance in Automotive Industry. Quality Innovation Prosperity, 23(1), 45-59. DOI: https://doi.org/10.12776/qip.v23i1.1203

Piechnicki, A. S., Sola, A. V. H., & Trojan, F. (2015). Decision-making towards achieving world-class total productive maintenance. International Journal of Operations & Production Management, 35(12), 1594-1621. DOI: https://doi.org/10.1108/IJOPM-11-2013-0479

Raouf, A. & Ben-Daya, M. (1995). Total maintenance management: a systematic approach. Journal of Quality in Maintenance Engineering, 1(1), 6-14. DOI: https://doi.org/10.1108/13552519510083093

Saaty, T. L. (1977). A scaling method for priorities in hierarchical structures. Journal of Mathematical Psychology, 15(3), 234-281. DOI: https://doi.org/10.1016/0022-2496(77)90033-5

Saaty, T. L. (1986). Axiomatic Foundation of The Analytic Hierarchy Process. Management science, 32(7), 841-855.

Saaty, T. L. (1990). How to make a decision: the analytic hierarchy process. European journal of operational research, 48(1), 9-26. DOI: https://doi.org/10.1016/0377-2217(90)90057-I

Saaty, T. L. (2008). Decision making with the analytic hierarchy process. International Journal Services Sciences, 1(1), 83-98. DOI: https://doi.org/10.1504/IJSSci.2008.01759

Sadeghi, A., & Manesh, R. A. (2012). The application of fuzzy group analytic network process to selection of best maintenance strategy-a case study in mobarakeh steel company, Iran. Procedia-Social and Behavioral Sciences, 62, 1378-1383. DOI: https://doi.org/10.1016/j.sbspro.2012.09.236

Sahoo, S. (2019). Assessment of TPM and TQM practices on business performance: a multi-sector analysis, Journal of Quality in Maintenance Engineering, 25(3), 412-434. DOI: https://doi.org/10.1108/JQME-06-2018-0048

Shafiee, M. (2015). Maintenance strategy selection problem: an MCDM overview. Journal of Quality in Maintenance Engineering, 21(4), 378-402. DOI: https://doi.org/10.1108/JQME-09-2013-0063

Sharma, A., Yadava, G. S., & Deshmukh, S. G. (2011). A literature review and future perspectives on maintenance optimization. Journal of Quality in Maintenance Engineering, 17(1), 5-25. DOI: https://doi.org/10.1108/13552511111116222

Sharma, M. & Kodali, R. (2008). TQM implementation elements for manufacturing excellence. The TQM Journal, 20(6), 599-621. DOI: https://doi.org/10.1108/17542730810909365

Sharma, V., Gidwani, B. D., Sharma, V., & Meena, M. L. (2019). Implementation model for cellular manufacturing system using AHP and ANP approach. Benchmarking: An International Journal, 26(5), 1605-1630. DOI: https://doi.org/10.1108/BIJ-08-2018-0253

Shinde, D. D. & Prasad, R. (2018). Application of AHP for ranking of total productive maintenance pillars. Wireless Personal Communications, 100(2), 449-462. DOI: https://doi.org/10.1007/s11277-017-5084-4

Singh, M., Sachdeva, A., & Bhardwaj, A. (2012). Measuring manufacturing performance with the implementation of TPM: an exploratory study, International Journal Productivity and Quality Management, 9(4), 456–471. DOI: https://doi.org/10.1504/IJPQM.2012.047192

Singh, R. & Kumar, H. (2017). Role of TPM Paradigms in Achieving Manufacturing Excellence in Industry, International Journal of Innovative Research in Science, Engineering and Technology. 6(8), 16624. DOI: https://doi.org/10.15680/IJIRSET.2016.0608116

Singh, U. & Ahuja, I.S. (2015). Evaluating the contributions of total productive maintenance on manufacturing performance, International Journal of Process Management and Benchmarking, 5(4), 425-455. DOI: https://doi.org/10.1504/IJPMB.2015.072324

Sivaram, N.M., Devadasan, S.R., Murugesh, R., Karthi, S., & Sreenivasa, C.G. (2014). Synergizing total productive maintenance elements with ISO 9001: 2008 standard based quality management system. The TQM Journal, 26(6), 534-549. DOI: https://doi.org/10.1108/TQM-08-2012-0059

Slack, N., Chambers, S., & Johnston, R. (2007). Operations Management. 5. ed. Edinburgh Gate, Harlow, Essex CM20 2JE: Prentice Hall / Financial Times / Pearson Education.

Sousa, J. V. (2017). Examinando as Perdas em Indústrias de SUAPE Conforme a Ótica do Lean System – 1 ed. Appris, Curitiba, PR.

Sousa, J. V., Jerônimo, T. B., Melo, F. J. C. & Aquino, J. T. (2017). Use of AHP to identify quality losses in manufacturing companies: a case study. Exacta, 15(1), 89-100. DOI: https://doi.org/10.5585/exactaep.v15n1.6691

Stefano, F. & Kojikovski, G. (2015). Every minute 7 people lose their jobs in Brazil. Revista Exame.com. 10 October 2015. Available at: http://exame.abril.com.br/revista-exame/edicoes/1099/noticias/a-cada-minuto-7-pessoas-perdem-o-emprego-no-brasil (accessed 5 December 2015).

Stevenson, W. J. (2014). Operations Management. 20. ed. McGraw-Hill Series in Operations and Decision Sciences, New York: NY.

Suape (Industrial Port Complex). (2017). Suape Complex, Available at: http://www.suape.pe.gov.br/complexo_suape.asp. (accessed 15 February 2017).

Takahashi, Y. & Osada, T. (1990). TPM: Total Productive Maintenance. Asian Productivity Organization, Tokyo.

Upadhyaya, G. & Bhat, S. (2016). The effect of contingencies on mutual influence among quality awards and quality initiatives. The TQM Journal, 28(6), 814-833. DOI: https://doi.org/10.1108/TQM-09-2014-0080

Van der Wal, R.W.E., & Lynn, D. (2002). Total productive maintenance in a South African pulp and paper company: a case study. The TQM Magazine, 14(6), 359-366. DOI: https://doi.org/10.1108/09544780210447465

Wind, Y., & Saaty, T. L. (1980). Marketing Applications of The Analytic Hierarchy Process. Management Science. 26(7), 641-658. DOI: https://doi.org/10.1287/mnsc.26.7.641

Downloads

Publicado

23.07.2021

Como Citar

Melo, F. J. C. de, Sousa, J. V., Aquino, J. T. de, & Jerônimo, T. de B. (2021). Utilizando o AHP para melhoria de processos de fabricação em TPM em um complexo industrial e portuário. Exacta, 19(3), 523–549. https://doi.org/10.5585/exactaep.2021.16693

Edição

Seção

Artigos