Aplicação do ciclo PDCA para redução do desperdício de embalagens de papelão: estudo de caso em uma indústria alimentícia

Abstract

Quality tools are indispensable to ensure continuous improvement and constant optimization of engineering process in industry, therefore essential on an Engineering course. In this context, this work aimed on analyzing and applying PDCA Method (Plan, Do, Check and Act) on a food industry, focusing on decreasing cardboard packaging waste. In order to achieve the purpose of the work, it was used the four steps of the method that are Plan, Do, Check and Act. On the first step, a process study was made, following the productive flow. It was also collected current and past data to compare the results. This data collect was made with the help of production operators that filled a spreadsheet with information about packaging waste, including the machine identification, date and the cause of discard. These spreadsheets were filled for 10 consecutive days, except on Sundays and then the data collected was stratified and analyzed using the Ishikawa Diagram and divided by the Pareto principle. With the results and another process flaws it was elaborated an action plan to block the main causes of packaging loss. On Do step it was followed the action plan, checking its efficiency or its need of rethinking the action proposed for the problem. On Check step, the implemented improvements were analyzed, evaluating if new actions and studies were needed. On this stage was also analyzed the financial and accounting gain of the project, showing its efficiency. At the last stage was applied the standardization of the improvements. After the conclusion of possible actions, it was applied trainings to the operators involved so the improvements are effective and become part of their regular activities. After applying the methods, it was possible to notice a waste reduction, as well as an increase of machine productivity.