Proposta inicial e desenvolvimento de plano de injetoras

Abstract

In the current scenario of high global competitiveness, the Brazilian manufacturing industry demands efficiency and cost reduction as essential factors for survival. In this context, the plastic injection sector stands out as a strategic supplier of components for several segments, such as the automotive, electronics, and consumer goods industries. This paper presents a case study on failure analysis and the development of an optimized maintenance plan for a plastic injection molding machine line in a company from the plastics sector. Based on the problem of a high incidence of unplanned downtime and the predominance of corrective maintenance, the study aims to demonstrate the feasibility of implementing a proactive maintenance management approach to increase asset availability and reliability. The methodology consisted of collecting and processing historical data from corrective maintenance work orders over a three-month period. The data were subjected to quantitative analysis using Pareto Analysis to identify the most critical equipment, as well as qualitative analysis to categorize the main failure modes. The results indicated that a small number of machines is responsible for most of the downtime, with recurrent failures in electrical and tooling systems. Based on this diagnosis, a detailed maintenance plan was developed, including preventive maintenance routines and guidelines for the introduction of predictive techniques, such as thermography. It is concluded that the transition from a reactive model to a planned, data- driven maintenance strategy is fundamental for cost reduction and increased production efficiency, with the proposed plans serving as a strategic tool to achieve these objectives.