A metodologia DMAIC como recurso para o aumento da capacidade produtiva em prensas industriais Manaus.

Abstract

The projected growth in demand presents tire industries with the challenge of expanding their production capacity to meet customer needs without requiring significant investments in new equipment. In this context, this study aimed to apply the DMAIC methodology to increase the production capacity of vulcanizing presses in a motorcycle tire manufacturing company located in the Manaus Industrial Park (PIM). The vulcanization process was identified as the bottleneck in the production line, as its long cycle time limited the final volume of tires produced. The research is characterized as applied, with a predominantly quantitative approach, exploratory-descriptive character. Data collection was carried out through time studies, systematic process observation, and analysis of production indicators. The machine cycle, benchmarking, and Spaghetti diagram tools were used to identify the root causes of process inefficiencies. Based on the results obtained, improvements in press operations were proposed and implemented, accompanied by a control plan to ensure the sustainability of the gains achieved. The implemented actions reduced the kinematic time from 1.48 to 1.17 minutes, resulting in a capacity gain of approximately 326 tires per day across the entire factory, exceeding the initial target of 313 tires per day. The results demonstrate that the systematic application of the DMAIC methodology, combined with Lean Manufacturing tools, constitutes an effective approach for eliminating waste and increasing production capacity without expanding the factory.