Projeto e simulação de uma aplicação de requisitos da Indústria 4.0 na logística interna: um caso em uma fábrica de fitas adesivas do PIM

Abstract

Internal logistics plays a strategic role in the operational performance of industrial systems, being influenced by factors such as plant layout, material handling systems, and the level of technological maturity. In the context of the Manaus Industrial Pole, the adoption of Industry 4.0 requirements is still incipient, particularly with regard to the digitalization and modeling of logistics processes. In this context, this dissertation aimed to use computer simulation to estimate the impacts of applying Industry 4.0 requirements and layout reconfiguration proposals on internal logistics, with a focus on the transportation and storage of finished-product pallets in an adhesive tape manufacturing plant located in the Manaus Industrial Pole. The research is characterized as applied, with a qualitative and quantitative approach, classified as exploratory and descriptive in terms of objectives, and as action research with respect to procedures. Data were collected through document analysis, interviews, on-site observations, and time studies of operational activities, and subsequently used to develop discrete-event simulation models in the FlexSim® software. Four simulation scenarios were developed: the current factory scenario, a scenario with load unitization, a scenario incorporating Industry 4.0–oriented technologies, and an additional scenario proposing a new layout and the definition of operational parameters. The simulation results demonstrated that the combined application of Industry 4.0 technologies, load unitization, and layout reconfiguration led to significant improvements in the analyzed logistics indicators, such as reduced internal movements, better utilization of material handling resources, decreased intermediate inventories, and increased operational efficiency. It is concluded that computer simulation proved to be a suitable and effective tool for evaluating improvement alternatives in internal logistics, supporting decision-making at operational, tactical, and strategic levels, as well as contributing to industrial competitiveness and to the advancement of scientific knowledge in the field of Logistics 4.0.