1. Increase in Productivity of the Iron Ore Loading Terminal.
- Author
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Viana Pestana, Ana Giorgia, Pereira da Costa, Fabio, Nunes da Silva, Fernando, Alves Pessoa, Gerisval, Miranda Souza, Jamison, Martins Pereira, José Magno, da Silva de Araujo, Manoel Maciel, Cardoso Nunes, Thiago, de Oliveira Pinheiro, Thiago, and Nunes Sobrinho, Valdeilton
- Subjects
IRON ores ,SUSTAINABILITY ,LEAN management ,COST control ,AIR pollution emissions prevention - Abstract
This article aims to present the application of the LEAN method to enhance performance in loading iron ore wagons at Vale's Carajás Railway in Brazil, specifically at the Serra Leste loading terminal. This terminal annually transports 4.3 million tons, loading over 40,000 wagons, with a projected increase in transportation by 66% in the coming years, reaching 7 million tons. The Serra Leste loading terminal faces the challenge of reversing the scenario of lower mean weight of iron ore wagons on the Carajás Railway, thereby contributing to Vale's strategic objectives of productivity, sustainability, and competitive all-in cost. Thirty MURI, MURA, and MUDA deviations were identified, and the goal was set based on historical data to support the production budget. Processes were then mapped using Pareto analysis, sequential chart, box plot, and histogram. Causes were identified, wagon loading steps were mapped, and a future scenario projection was made with a 50% reduction in steps, incorporating LEAN assumptions. Subsequently, an effective action plan was implemented. The project yielded gains in productivity, sustainability, and cost, adding 3.92 tons of iron ore to each wagon, achieving the best Vale mean weight, resulting in a reduction in costs of US$ 141,043.10, a decrease in diesel consumption by 134,340 liters, and a reduction in emissions of 383,296 kg of CO² eq. The project brought stability, repeatability for over 16 months, and established new records for the mean weight of wagons at Vale. [ABSTRACT FROM AUTHOR]
- Published
- 2024
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