Rastreabilidade de anomalias na montagem de veículos de passeio: estudo de caso

Abstract

The modern automotive industry faces the challenge of ensuring vehicle quality while maintaining an efficient production pace. This work addresses the traceability and anomaly recovery process in electrical components during the assembly of passenger vehicles. The objective is to enable early detection of anomalies by verifying each electrical component in the assembly process, allowing for immediate recovery and/or replacement, thus contributing to the improvement of the quality of the vehicles produced. Traceability plays a crucial role in the production chain, allowing for the monitoring and tracking of each component throughout the assembly process, from each part in each vehicle to its distribution to the final customer. The research-action methodology was used as it seeks to investigate the interactions between the researcher and the subjects involved in the events and aims to transform reality through

collaboration between both in the study process. In the case of the automotive industry, non- conformities in the assembly line are a routine occurrence, which must be reduced to a

minimum, preventing cars with any faults from reaching customers. In the research environment, the detection of faults in electrical components is carried out using: a) Body Control Module (BCM); b) Engine Control Module (ECM); and c) Radio and Urea Control Unit, with vehicle testing conducted using automotive diagnostic equipment (DSA). Therefore, the proposal is to transfer the automotive diagnostic equipment (DSA) to the production line designated as chassis 4, where fluid filling (urea, battery connection) is performed, and then the vehicle is started to verify the correct functioning of the electrical components. When there is a fault in the electrical component, the production team can take corrective actions (repairing the component or replacing it with another one), allowing for more efficient production actions. This research has brought significant gains both to the researcher and the company. For the researcher, it provided a valuable opportunity to enhance skills and knowledge, especially in the field of automotive diagnostics and quality management in vehicle production. It also provided the opportunity to develop the ability to identify and address electrical component faults early, which is a valued competence that can boost the researcher's career in the automotive sector. In turn, the company reaps substantial benefits from the successful implementation of this new procedure. This translates into more efficient production, resulting in time and resource savings. This new procedure consists of: a) Relocation of the Automotive Diagnostic Equipment (DSA); b) Verification of Electrical Components in the new location (chassis 4); c) Real-time Anomaly Identification; d) Efficient Corrective Measures; e) Time and Resource Savings (corrections will be made before the vehicle progresses in the assembly process). This quality improvement strengthens the company's reputation, contributes to customer satisfaction, and, consequently, may boost greater market share.