Franco da Silveira
Universidade Federal de Santa Maria (UFSM), Brazil
E-mail: franco.da.silveira@hotmail.com
Filipe Molinar Machado
Universidade Federal de Santa Maria (UFSM), Brazil
E-mail: fmacmec@gmail.com
Janis Elisa Ruppenthal
Universidade Federal de Santa Maria (UFSM), Brazil
E-mail: profjanis@gmail.com
Leonardo Nabaes Romano
Universidade Federal de Santa Maria (UFSM), Brazil
E-mail: romano@mecanica.ufsm.br
Marcelo Silveira de Farias
Universidade Federal de Santa Maria (UFSM), Brazil
E-mail: silveira_farias@hotmail.com
Luis Cláudio Villani Ortiz
Universidade Regional Integrada do Alto Uruguai e das
Missões, Brazil
E-mail: ortizluis@bol.com.br
Submission: 28/10/2017
Accept: 06/03/2018
ABSTRACT
One
of the problems of multiple variables and constraints that is found in the
productive systems of the companies and is responsible for influencing the
final quality of the product is the proper selection of the material used in
the manufacturing. Thus, in order for there to be no divergences between
specification and design requirement in the process, effective guidelines are
required to verify their conformity upon receipt. The verification is carried
out by means of technical tests, on other hand, to obtain the characteristics
of the mechanical properties of the same. The general objective of this paper
is to present systematic proposals for the preparation of quality assurance of
mechanical tests on the reception of metallic materials applied to the
development of agricultural machinery. In methodological terms, a Systematic
Literature Review (SLR) was applied and multiple cases were studied. This
research is classified as descriptive and comparative, of an exploratory nature
that uses a set of data collection, analysis and treatment actions, in order to
assist in the development of planned and organized activities that make it
possible to implement the necessary tests for the correct qualification of the
material received by the companies. The results present a systematic
proposition that can be adopted in the accomplishment of mechanical tests in
metallic materials in the control of reception in companies that develop
agricultural machines and that can help other market segments.
1. INTRODUCTION
With
the presence of factors such as high competitiveness and economic globalization
in the industrial sectors, as organizations increasingly seek to adapt as
market changes (SIMÕES et al., 2013, SCHÖNERER; WAGNER, 2016). It is necessary
that, as developed companies, organizational and productive restructuring, with
the purpose of forcing new implementations and technological modifications,
which will result in the expansion of its organizational businesses (MOHAGHEGHI;
APARICIO, 2017).
As
a consequence of the exposure, an adoption of a Quality Management System (QMS)
is vital in many companies, especially in taking strategic positions that have
advantages over competitors (CATER-STEEL; LEPMETS, 2014; RABIEH et al., 2016).
The
implementation of a specific QMS for the laboratory environment of the company
has the purpose of delivering reliable and traceable results throughout the
production system. A number of authors argue that the introduction of a QMS and
the accreditation of laboratories according to standardization are not easy
tasks (KONOVALOVA; POPOVA, 2010; GROCHAU; CATEN, 2012; RUIZ-TORRES et al.,
2017).
According
to Abdel-Fatah (2010), the technical competence of the laboratories becomes
critical for the manufacturer, supplier, exporter and the consumer, which
reinforces the importance of the implementation of management systems for
testing and calibration laboratories.
As
regards standards, the main one is NBR ISO/IEC 17025. It is an international
standard aimed at the laboratory environment, which is responsible for
determining the necessary requirements for testing and calibration laboratories
to demonstrate their technical competence and the validity of the results
provided (ABNT, 2005; GROCHAU; CATEN, 2012; SILVA et al., 2015).
In
order to obtain the so-called "accreditation", the testing
laboratories must meet a number of factors, including monitoring the validity
of the mechanical tests performed (GARCIA; SILVA; PEREIRA, 2015; SABBAGHA et
al., 2016). Therefore, the quality assurance of the test results is directly
associated to the process flow. The methods can include internal comparisons,
proficiency testing, test replication, control chart usage, among others and
are necessary to avoid problems that relate to the technical specifications of
the final product (LIXANDRU, 2016; RABIEH et al., 2016).
The
design and implementation of an organization's QMS is influenced by different
needs, specific objectives, products supplied, processes employed and by the
size of its organizational structure. To be effective, the QMS should identify
and manage the various interrelated activities (RABIEH et al., 2016).
In
this context, when an activity is dependent on the subsequent one and both are
managed in a way that allows the transformation of inputs into outputs, they
can be considered a process (SANTOS, 2010). The main factors that influence the
process and, consequently, the end product, are the material, part or component
received from the supplier.
Thus,
in order to obtain satisfactory results, it is necessary to have an efficient
performance of the sectors involved in the project (ROZENFELD et al., 2006;
HOSSEINIJOU et al., 2014; VELDEN et al., 2015).
The
ISO 9000 (ABNT, 2010) standard establishes requirements that help improve
internal processes, monitor the work environment, increase employee
qualification, and verify the satisfaction of customers, employees and
suppliers, as part of an ongoing process to improve QMS.
The
requirements apply to areas such as materials, products, processes and services
(ABNT, 2010). For the different classes of standardizations ISO 9001 is used,
which explains the requirements that must be adopted for inspection and testing
before the product is shipped by the supplier and upon receipt by the customer.
In
addition, for conformity conferencing, the standard refers to inspection,
measurement and testing equipment that guide the quality of the product being
shipped and received, as well as the final process (RAUBER et al., 2014;
PEREIRA; GRACIANO; VERRI, 2016).
The
determination or knowledge of the mechanical properties is relevant for the
selection of materials as well as for their application. Properties are
responsible for defining the behavior of the material that is subject to
mechanical stresses during the process or service (CALLISTER JÚNIOR, 2006).
The
properties can be obtained by means of mechanical tests, which are standard
methods. Standardization is important so that there is a common language
between suppliers and users/customers of materials (SOUZA, 1995; GARCIA; SPIM;
SANTOS, 2012).
In
this sense, this study aimed to present systematically propose guidelines for
the preparation of quality assurance of mechanical tests on the receipt of
metallic materials applied to the development of agricultural machinery. In
order to do so, the work begins by presenting a theoretical rescue on the
quality management system, its main aspects of implementation and benefits
generated for the company and its suppliers.
In
addition, we emphasize the quality assurance of testing laboratories and
fundamentals of mechanical tests on materials. Subsequently, the methodological
approach that was used in the empirical part of the study is presented. In the
sequence, the results are presented and, finally, the conclusions of the work.
2. BACKGROUND
2.1.
Quality
Management System
The
importance of Quality Management System (QMS) is directly related to the
company's processes and how to improve the quality of products and services to
customers (SILVA et al., 2015). The QMS is an organizational strategy used to
deal with the diversities arising from a constantly evolving economy (PEREIRA,
2015).
Material
selection is one of the key elements that actively acts in business strategies.
Thus, the suppliers choice for their production chain represents a continuous
improvement, aiming to guarantee the improvement in the processes that involve
the different components and services acquired (GALDAMEZ; LOPES, 2013).
Figure
1 exemplifies the information process and the flow of materials involved in the
decision-making process for product manufacturing, which should be optimized to
reduce consumer waiting time.
Figure 1: Flow of materials and information in
business logistics.
Source:
Adapted from Slack et al. (1999).
One
of the factors of great importance to obtain greater assurance of the
conformity of the materials received is to identify and select the suppliers
correctly. The supplier selection process is not simple and the complexity
increases depending on the characteristics of the item to be purchased
(MOHAGHEGHI; APARICIO, 2017).
The
ISO 9001 standard provides a set of standardization for a given service or
product and specifies the requirements for a QMS that can be used by
organizations for internal application, certification or for contractual
purposes that seek to meet customer requirements (RAUBER et al., 2014, NOGUEIRA;
DAMASCENO, 2016).
With
the implementation of the standard, there is a relationship of trust between
the company and the client results. An organization that has a QMS according to
ISO 9001 can request certification and obtain the "ISO 9001 compliance
seal" (ABNT, 2015).
It
should be noted that the QMS has the function of helping the manager to find
and correct inefficient processes that occur in the organization (SILVA et al.,
2015; PEREIRA; GRACIANO; VERRI, 2016). The adoption of a QMS is a strategic
decision and its development and implementation are specific to each type of
organization. The main objectives of a QMS are: i) to meet customer
requirements in order to increase customer satisfaction; ii) obtain a view of
the organization using the process approach; iii) ensure continuous process
improvement; iv) measure and evaluate the results of the performance and
effectiveness of the process; and v) continuously monitor customer satisfaction
(ABNT, 2015).
Thus,
it is noted that ISO 9001 aims to provide confidence that the supplier can
consistently and repetitively supply goods and services as specified. Thus, the
ISO 9001 certified supplier is characterized by meeting the requirements of ISO
9001, for establishing a systemic approach to quality management and for
managing its business in such a way that it ensures that its needs are
understood, accepted and (ABNT, 2015). Table 1 shows the different requirements
that are determined by ISO 9001 and that contribute to a correct acquisition of
products or materials.
Table 1: Main objectives of ISO 9001.
Factors |
Conditions |
Specifications |
Acquisition
of Products and Services |
Acquisition Process |
The organization
shall ensure that the product purchased complies with the specified
procurement requirements. The type and extent of control applied to the
supplier and the product purchased should depend on the effect of the product
purchased on subsequent product realization or on the final product. |
Acquisition
Information |
Procurement information should
describe the product to be procured and include, where appropriate,
requirements for: a) product approval, procedures, processes and equipment;
b) qualification of personnel; and c) quality management system. The
organization shall ensure the adequacy of the specified procurement
requirements prior to its communication to the supplier. |
|
Verification of Purchased Product |
The organization shall establish
and implement inspection or other activities necessary to ensure that the
product meets the specified procurement requirements. |
|
Production and Supply of Services |
Control of Production and Service Provision |
The organization shall plan and
perform production and service provision under controlled conditions.
Controlled conditions shall include, where applicable: a) the availability of
information describing the characteristics of the product; b) the
availability of work instructions, when necessary; c) the use of adequate
equipment; d) the availability and use of devices for monitoring and
measurement; e) the implementation of measurement and monitoring; and f) the
implementation of the release, delivery and post-delivery activities. |
Control of Measuring and Monitoring Devices |
Where it is necessary to ensure
valid results, the measuring device shall be: a) calibrated or checked at
specified intervals or before use, against measurement standards traceable to
international or national measurement standards; when this standard does not
exist, the basis used for calibration or verification shall be recorded; b)
adjusted or readjusted, when necessary; c) identified to enable the
calibration situation to be determined; d) protected against adjustments that
may invalidate the measurement result; and e) protected from damage and
deterioration during handling, maintenance and storage. |
Source: Adapted from ABNT (2015).
The
organization shall plan and implement the necessary monitoring, measurement,
analysis and improvement processes to demonstrate product or material
conformity. It should be noted that for inspection and testing ISO 9001
requires that the raw material be inspected (by documented procedures) prior to
use; that inspection, measurement and testing equipment shall receive
procedures for calibration/measurement, control and maintenance; that for the
inspection and testing situation there should be in the product or material
some indicator that shows what inspections and tests it has passed and whether
it has been approved or no.
2.2.
Quality
Assurance of Testing Laboratories
The
presentation of reference documents, replication of retained item essays and
participation in reference documents, replication of retained item essays, and
participation in intra-laboratory and interlaboratory programs. In accordance
with an ISO/IEC 17025 (ABNT, 2005; GROCHAU; CATEN, 2012) standard specifies the
requirements for quality assurance of test and calibration results in section
5.9, the laboratory shall have a quality control procedure to monitor the
validity of the tests and calibrations performed. In addition, the resulting
data must be provided according to trends and detectable, where practicable,
statistical techniques should be applied for critical analysis of results.
Dicla/Cgcre
mentions the requirements regarding the participation of laboratories in
proficiency testing activities through the NIT-DICLA-026 standard. In the case
of non-compliance by laboratories accredited in ISO/IEC 17025, this constitutes
non-compliance, since item 4.1.2 emphasizes that it is "the responsibility
of the laboratory to carry out its testing and calibration activities in order
to meet the requirements of standardization and meet the needs of customers,
regulatory authorities or organizations that provide recognition” (ABNT, 2005;
INMETRO, 2011).
In
addition, item 9.1 of NIT-DICLA-026 refers to the general policy for
participation in proficiency testing, in which laboratories must demonstrate
the technical competence in performing the accredited tests and calibrations
through satisfactory participation in proficiency testing (TP) where they are
available. If there are no TP activities available at the required frequency,
the laboratory must demonstrate by other mechanisms that it has technical
competence. After obtaining accreditation, the laboratory must participate in
at least one TP activity for each significant part of its accreditation scope,
every four years (INMETRO, 2011).
2.3.
Mechanical
Tests on Materials
The
design of any mechanical component, or any engineering project, requires a
thorough knowledge of the properties, characteristics and behavior of the
materials. From the practical point of view, the mechanical properties stand
out with greater importance in the engineering, since they are related to the
resistance of the metals that are subjected to efforts of mechanical nature.
Based on their determination and knowledge, all metallic components used in
industry and fixed and mobile structures are designed, calculated and executed
(CALLISTER JÚNIOR, 2006).
Some
industries use tests to control production, and are called routine tests. They
are performed in analysis laboratories or in industrial machines, with no need
for precision, and a machine error of up to 1% can be admitted. However, when
they aim to obtain mechanical properties for research or study of materials,
they use more precise machines, increasing reliability. Thus, control devices
with a high degree of precision are required, unlike ordinary machines used in
companies for routine tests (SOUZA, 1995; ASKELAND, 2012). In addition, it is
important to emphasize the performance of tests in specialized laboratories,
since the development and improvement of the products depend significantly on
the availability and quality of mechanical and technological tests (SHIGLEY,
2005).
According
to Garcia, Spim and Santos (2012), the mechanical properties of the metallic
materials are determined through several tests, where they can be destructive,
where the rupture or destruction of the part and the test or non-destructive
component occurs, which are used to detect internal faults in parts and
components, not causing them to become unusable. The tests shall be performed
according to the geometry of the part and component, the manufacturing process
and according to the current technical standards. The methods of testing may be
by means of part or component tests, model tests, sample tests, and tests on
specimens taken from part of the structure (CALLISTER JÚNIOR, 2006; ASKELAND,
2012).
2.4.
Agricultural
Machinery Development Process
The
Agricultural Machinery Development Process (PDMA) is used in the context of the
Brazilian companies of the industrial sector of agricultural machinery to
guarantee important competitive advantages against the market competitors
(OLIVEIRA; DALLMEYER; ROMANO, 2012; SILVEIRA; MACHADO; RUPPENTHAL, 2017).
Figure 2 represents the reference model, which aims to disseminate knowledge
about the PDMA process and its formal practices.
Figure 2: Process, macro phases and phases of the
reference model for PDMA.
Source:
Adapted from Romano (2013).
The
reference model encompasses a planning macro phase, which covers the planning
phase of the project itself; a macro phase of design, which involves the
elaboration phases of the informational, conceptual, preliminary and detailed
designs of the product and the manufacturing process; and the implementation
macro phase, which includes the phases of production preparation, market
launch, validation of the agricultural machine and closure of the project
(ROMANO, 2013; BERGAMO; ROMANO, 2016).
In
general, as practices that seek to achieve improvements in cost, time, and
manufacturability are related to the informational design phase in PDMA. Figure
3 represents how tasks are part of the information design phase, which is
intended to define the design specifications of the agricultural machine and is
responsible for establishing a presentation by the agricultural machine design
plan.
Figure 3: Informational Design PDMA.
Source:
Bergamo and Romano (2016).
The
phase of the informational project is characterized as the moment of the
project to collect and analyze a set of information that specifies the product
with the greatest clarity in order to guide the generation of future project
solutions. Design is the second macro phase of the PDMA, which begins with the
informational project that is responsible for defining the design
specifications of the agricultural machine, according to Figure 3, and
consolidate the product requirements from information from sources such as
customers, vendors and the competition to deploy them in design specifications.
3. METHODOLOGY
The
research methodology adopted to conduct the theoretical part of the present
study was the Systematic Literature Review (SLR). The SLR is a methodology that
uses as a data source the existing literature on a given topic, selects and
evaluates contributions, analyzes and synthesizes data. It describes the
evidence in order to allow clear conclusions about what is already known, as
well as what is not known about the subject matter in question (DENYER;
TRANFIELD, 2009).
Were
selected the databases Google Academic, ISI Web of Science, SciELO, Science
Direct and Scopus. The scope of the literature review includes articles
published in journals and journals that deal with mechanical tests, metal
materials, quality management, mechanical testing laboratories, laboratory
quality assurance, test accreditation, standards for testing metal materials,
materials.
The
databases were selected for presenting more comprehensive and thus enable the
identification of information to improve the context of the research theme. The
scan is characterized as theoretical-conceptual (LOPES; CARVALHO, 2012).
The
scope of SLR includes articles published in periodicals and journals dealing
with mechanical testing, quality management and laboratory quality assurance.
It was necessary to adopt logical operators available for advanced searches,
thus, the keywords (without quotes and without refinement by area of knowledge)
to be used in the theoretical survey in the databases were established.
After
searching the databases, the refinement of the research considered all
available years and adopted the criteria of language (Portuguese/English),
types of documents (article/review).
After
application of the initial filters, approximately 37 articles were identified.
It should be noted that the chronological survey of articles is allocated
according to the search string. Considering the searches made in the selected
databases, the research reference points were defined, which compose the
synthesis set elaborated on each one of the topics listed in the general
structure of the article.
Subsequently,
the articles were analyzed from the literature found and, thus, a synthesis of
each of them was carried out, presenting its main characteristics. There were
also identified none articles in which there are intersections between the
themes and that were later analyzed in the light of the mentioned research
questions. The analysis was done with the help of Mendeley and NVivo®
software.
In
the second part of the research, from the flow illustrated in Figure 4 and
Figure 5, the steps that were necessary for the practical accomplishment of the
research are sequentially observed. The initial stage was the formulation of
the research problem and its delimitation, where an interface between the material
selection area and the logistics was carried out. The general and specific
objectives were then elaborated. In the third stage, the theoretical study was
done, as a way of knowing the state of the art on the areas of interface,
material selection and logistics.
Figure 4: Activities conducted to conduct research.
Source:
Authors (2017).
In
the fourth stage, through the theoretical study, the general framework of
variables and indicators was determined. In the fifth step, the candidates to
compose the guidelines were selected from the table of variables and
indicators. In the sixth stage, the theoretical guidelines were elaborated, in
the form of a flowchart, through the selected indicators.
In
the seventh stage, the model was discussed and the need to optimize it was
verified. Figure 5 depicts the flow of the steps described above. In addition,
it is noteworthy that the data collection was performed based on the structured
questionnaire applied in companies and the results obtained in this research underwent
a statistical analysis process.
The
questionnaire was sent to 20 companies in the metal mechanics sector, located
in the northwestern region of Rio Grande do Sul (RS), from January to May 2017.
Figure 5: Activities conducted to conduct research.
Source: Authors (2017).
The
questions in the questionnaire were related to the procedures and tests used to
receive metallic materials. In the questionnaire, information regarding the
main metallic materials purchased was considered; number of suppliers for each
material; the function of the acquired material; the specifications of the
materials required in the acquisition; to the selection process carried out by
the company; the use of logistics information in the selection of material; the
details of catalogs; to the company's view on a system that selects material
and supplier at the same time, based on the interrelationship between technical
material information and logistical information. In order to maintain the
confidentiality of the companies, numbering was used to characterize them. The
procedures used to analyze the information were: coding of the answers,
tabulation of data and interpretation of the particularities. The Microsoft
Office® Excel 2013 tab was used.
4. RESULTS AND DISCUSSIONS
The
characteristics of the respondent and the company of each of the questionnaires
applied can be observed in Table 2. It can be verified that the responses were
from companies of different sizes, as medium-sized companies (with 100 to 499
active employees) or as large (with 500 or more active employees).
Table 2: Characterization of the respondent and the
company.
Company |
Sector of the Respondent |
Respondent's Position |
Company Activity |
Number of Employees |
|
Present Laboratory for Receiving and Testing Material |
1 |
Production |
Management |
Manufacture of
Agricultural Components |
250 |
20 |
- |
2 |
Shopping |
Purchasing Assistant |
Parts and
Agricultural Implements |
150 |
18 |
- |
3 |
Quality |
Quality Inspector |
Manufacture of
Agricultural Implements |
2500 |
56 |
ü |
4 |
Quality |
Quality Inspector |
Metallurgy |
200 |
25 |
- |
5 |
Production |
Production
Coordinator |
Machines and
Equipment |
500 |
30 |
ü |
6 |
Production |
Production Manager |
Casting and Machining |
900 |
42 |
ü |
7 |
Warehouse |
Warehouse Coordinator |
Parts and
Agricultural Implements |
1500 |
65 |
ü |
8 |
Shopping |
Purchasing Manager |
Metallurgy |
350 |
25 |
- |
9 |
Shopping |
Purchasing Assistant |
Metallurgy |
100 |
16 |
- |
10 |
Production |
Production supervisor |
Foundry |
300 |
30 |
- |
11 |
Shopping |
Business Analyst |
Machines and
Implements |
250 |
22 |
- |
12 |
Warehouse |
Auxiliary Warehouse |
Metallurgy |
200 |
32 |
- |
13 |
Production |
Production Supervisor |
Machines and
Equipment |
180 |
17 |
- |
14 |
Quality |
Quality Manager |
Agricultural
Machinery |
75 |
16 |
- |
15 |
Management |
Production Manager |
Agricultural
Machinery |
240 |
31 |
- |
16 |
Project |
Project Leader |
Metallurgy |
175 |
19 |
- |
17 |
Product |
Product Director |
Machines and
Equipment |
90 |
14 |
- |
18 |
Laboratory |
Laboratory Chief |
Lifting Machines |
160 |
20 |
- |
19 |
Quality |
Quality Inspector |
Machines and
Implements |
210 |
26 |
- |
20 |
Quality |
Quality Inspector |
Agricultural
Machinery |
195 |
21 |
- |
Source: Authors (2017).
All
the companies interviewed stated that they have differences in the metallic
products received by the suppliers. For 67% of the companies, they are made in
metallic products received from suppliers and suppliers for 33% of companies
and frequency of inspection performed weekly. It should be noted that the
lowest percentage of reference in medium-sized companies, which is a smaller
number of suppliers. In addition, 50% are satisfied with the sampling control
currently used by them and 50% are not fully satisfied with the present system
to verify the conformity of the metallic materials received.
When
questioned about the existence of own laboratories to analyze the metallic
materials received, 75% of the companies reported that they have equipment and
25% do not have any type of equipment with these ends and that they end up
outsourcing this service. Thus, it was verified that the durometer is used in
67% of the companies as a method of verification of the metallic materials
received, the spectrometer is used in 25% of the companies and in 17% the
microdurometer. None of the companies has a tensile testing machine and 25%
said they do not have any machines for inspection.
Figure
6 shows the percentage of trials that are outsourced by companies. It was
verified that 58,33% of the companies interviewed outsourced the chemical
analysis, because they did not have the necessary equipment to obtain the
percentage of each chemical element in the material; 50% of the companies
outsource the traction test; 25% of companies outsource the hardness test; and
16,67% of the companies interviewed do not outsource any type of trial.
Recalling that the type of test varies according to the needs of the company
and the characteristics of the material that the company wishes to analyze.
Figure 6: Trials outsourced by companies.
Source:
Authors (2017).
Figure
7 refers to the investments in technology areas presented by the companies
participating in the research. From the question about the acquisition of
machinery and equipment, laboratory implantation, technology acquisition, and
development/optimization of the process of compliance control in the receipt of
material, the percentage was the same for both questions, resulting in 66.67%
of the companies interviewed have invested in the last two years and intend to
invest in the next two years in these technological areas.
In
addition, 25% of the companies replied that there was no investment in the last
two years, but they intend to invest in the next two years. Only 8% of the
companies responded that they invested in the last two years and do not intend
to invest in the next two years; and 8% of the companies did not invest in the
last two years and do not intend to invest in the next two years in technological
areas.
The
results expressed by Figure 7 are directly related to the development of new
products in Brazilian companies, which, according to studies by Iacono and
Nagano (2016), this occurs predominantly in the internal environment of the
industry, with little involvement of external partners.
In
Brazil, there is a predominance of process innovation in relation to product
innovation (SOARES et al., 2016). Through a survey by PINTEC (IBGE, 2013),
approximately 17.3% of Brazilian companies implemented product innovations,
while 31.7% implemented process innovations, thus maintaining the innovation
model based on the access to technological knowledge through the incorporation
of machines and equipment (IBGE, 2013). However, the model is not shared by
more developed countries, in which the percentage of companies with product
innovations is larger or similar to that of companies with innovations in
processes.
Figure 7: Investments in technological areas.
Source:
Authors (2017).
To assist
companies in the design and product development activity, it is verified that
for the determination of an end product according to the established
requirements, a suitable QMS should be used. Thus, based on ISO 9001, Figure 8
shows the operational workflow for quality control in the reception of metallic
materials.
Figure
8 denotes material selection that meets specification as an important step in
the product development process. However, the selection of materials cannot be
done independently of the manufacturing process, and the selection of the
manufacturing process depends on other design factors, such as the listing of
properties and laboratory resources (ROZENFELD et al., 2006).
As Romano (2013)
points out, as production scheduling of the pilot batch is implemented,
production and supply personnel should monitor the timing of receipt of the
components and the approval certificates of samples, considering that it may
occur of components not yet certified. In this situation, product design,
manufacturing, quality and supply personnel should follow up on these
components, evaluating whether they can be used even with a failed sample
approval certificate.
Figure 8: Systematic proposal for the flow between
receiving materials and informational Design.
Source:
Authors (2017).
In
summary, the results and analyzes of the empirical research on the subject of
the study reveal that most of the companies in the studied metalwork sector do
not have specific characteristics that make the company adequate regarding the
operational flow of receiving materials, according to Figure 8.
In
many of the companies studied (62%) do not have specific mechanical testing
machines for metallic materials, thus compromising the correct specification of
the composition of the material and its necessary tests. In addition, they
usually group the materials received, albeit informally, in categories or
logistic segments (52%) and use mainly as a basis of classification the aspects
determined by the operator or directly by the invoice receipt (61%).
The
companies that do not have systematic and defined strategies for the adequate
flow of material tests on receipt represent (53%) of the population of the
sample. The organizations that do not present mechanisms and professionals for
the recognition of tests are (56%) and most of them need to perform mechanical
tests in the reception of metallic materials for conference (95%) and knowledge
of their properties (90%), before directing them for their proper purpose, thus
avoiding failures or even loss of materials, components and/or parts.
It is
important to emphasize that investments in equipment for conducting inspections
of metallic materials received are of fundamental importance in order to
guarantee the conformity of the material that will be used for (95%) of the
companies. Moreover, it is stressed that the lack of coordination between
government, companies and universities has been one of the main characteristics
of the Brazilian innovation system. However, much progress has been made since
the 1980s, thanks to government initiatives to bring the academic, public and
private spheres closer together (TORKOMIAN et al., 2016; BARBOZA; FONSECA;
RAMALHEIRO, 2017).
The
companies stated that there are other factors that influence to obtain
satisfactory results in the quality of materials received (60%), such as:
identify and select suppliers correctly; the buyer must be a professional
qualified to perform such activity and the applicant must specify in a correct
manner the characteristics of the material to be purchased. In this context, it
is important to mention that the role of the government is to create mechanisms
of direction and solutions favorable to innovative activities, also involving
cooperation between academia and industry in Brazil. Of particular note is the
precarious Brazilian performance in the business environment, with the
bureaucracy involved in the processes to open, maintain and close a business,
since Brazil occupied the 137th position among 143 countries surveyed in this
category in 2014 (CORNELL UNIVERSITY, 2014).
Finally,
the conceptual framework of the guideline developed according to Figure 8,
besides being based on the recommendations of theorists and business agents,
presents a systematic proposition that can support future academic research in
the field of study, as well as assist in the analysis and identification of
deficiencies in laboratory practice and in receiving materials.
Thus,
the flow between the receipt of materials and the informational project
developed in the research can help companies from other market niches that need
dependability with their products and respective clients. In addition, the
integration proposition of Figure 8 can help organizations of different sizes
face the challenges related to ISO 9001 certification as they point out the
problems found in the research conducted by the authors Ferreira et al. (2015).
5. CONCLUSIONS
The
quality management of metallic materials in the industrial sector is complex,
since the laboratory procedures that seek to meet the specifications have
differences in the metallic products received by the suppliers in all the
companies analyzed. To assist in the lack of information that deals with the
research topic, the operational workflow was developed for quality control in
the reception of metallic materials. However, for each methodological step to
be successful it is important to consider its particularities and the time of
implementation.
Based
on the mentioned considerations, some recommendations should be considered by
the companies of the metallurgical sector studied, on systematics, techniques
and forms of implementation, if they intend to obtain better results with the
application of the strategies expressed by the operational flow of receiving of
materials, such as: identification of process flows for receiving mechanical
tests for metallic materials using appropriate research methods and
multivariate statistical techniques; investment in updating and laboratory
formalization, including training of employees, partners, intermediaries and
specialists; and regarding competitive differentiation, it is suggested that
companies in the metal mechanics sector establish their laboratory strategies
based on more deliberate, deliberate and conscious decisions to enable a
greater effort in effectively implementing the differentiation strategies
identified.
Finally,
the study provided some relevant academic contributions and allowed the
advancement of knowledge about the application of guidelines for conducting
mechanical tests on metallic materials. In addition, the research represents an
extension of the academic study on laboratory norms, mechanical tests and
reception of metallic materials. However, despite the methodological care and
efforts undertaken to ensure the quality and validity of the results, the study
is subject to several types of limitations that need to be addressed. The
recognition of these limitations does not detract from the article nor devalue
the results, but it allows the more correct and conscious future use of data,
results and analyzes of this study.
The
main types of study limitations relate to the non-probabilistic and trial
method of sampling, which prevents the inference or generalization of the
results and restricts the conclusions of the survey to the companies studied
and also to companies that have omitted certain details or data strategic
information, secrecy policy or that the study involves competitors, which may
have caused some distortion in the results.
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