Designing a Novel System for the Introduction of Lubricant in Control Cables for the Automotive Industry

Abstract

The increasing competitiveness installed in the automotive industry implies continuous improvements in all fields of knowledge and action. Thus, it is very important to be aware of the wastes generate across all the productive and logistics operations. In this regard, and considering the production process of command cables for the automotive industry, it was detected that a significant volume of lubricant is wasted during the task of introducing grease into the spiral used in the command cables utilized to drive the doors, windows and brakes of motor vehicles. The industrial operation was carefully followed leading to identify the main causes of the wastes and a brainstorming was carried out allowing the discussion of new ideas on how to overcome the problem. A novel equipment was developed, being also cared all the logistics around the supplying task. The new solution developed, as well as the redefinition of the logistic process of supplying the lubricating grease to the production lines, made it possible to make the process more flexible for the admission of different grease packs, as well as a better utilization of the existing grease in the reservoirs, resulting in a cut of grease waste by more than 70%. It was also produced a prototype of the grease supply system, which allowed validate the previously developed system.