Advances in Automation and Cost Reduction in Spark Plugs Pressing System

Abstract

Abstract. This study deals with the gain in quality and cost reduction in the pressing of the spark plug wires from the need to ensure a standard, eliminate quality defects such as poor contact of the cables generating low power failures and unexpected problems. The main objective is to study the best practices in the automotive market, to ensure a standard for¯xing the spark plug wires, comparing them with the current method, pointing out potential gains from the analysis of deployment costs by reducing the time of labor and applying the results in the production line to ensure that the spark plug wires come out correctly set. To understand this work some key points were studied and addressed such as the system World Class Manufacturing (WCM), quality tools like FMEA, PDCA cycle and Kaizen. These were applied in the process of pressing the plug wires, highlighting their advantages and disadvantages, seeking the best way to use. The results show the implementation of automation to press the spark plug wires in a positive manner towards the operation performed by the operator. Automation was accepted and used to run the company in 2014. Referring to the layout of the production area, there was a reduction in the cycle time of the post. Moreover, reducing the cycle time of the operator with consequent cost savings for the company and improved ergonomic operation was observed. It is concluded that the main goal, which was to ensure a standard for pressing the plug wires and eliminating quality defects, was achieved as evidenced by cost analyses, beyond the desaturation of the job, thus receiving new activities.