Aplicação da metodologia Kaizen para reduzir o refugo inerente ao processo no corte de barras em uma seção de usinagem

Abstract

As a consequence of the increasing competitiveness among companies, the identification and reduction of losses and waste of processes have become crucial for reducing costs and guaranteeing competitive advantages for these companies. In this sense, Kaizen is a philosophy of the utmost importance to ensure continuous improvement and combating waste from World Class Manufacturing, also known as WCM. The present study has the general objective of identifying possibilities for reducing waste in the process of cutting bars in a machining section, where the waste inherent in the process stands out as the most relevant. To carry out this study, it was necessary: to map the current bar cutting process, analyze the data and apply the Kaizen tools to identify and implement improvements. After this step, it was possible to identify that the main reason for the high waste, annual average R$555.361, was related to the standard length of the bars used in the process, as they did not guarantee a good physical arrangement of the cutting process and there were many leftovers after this operation. After taking some actions aimed at the procedure for carrying out the activity and redefining the standard length of 3 of the 6 bars used in the process, it was possible to reduce R$396.780 with scrap inherent in the process of these materials. For this project, the type of quantitative-descriptive research was used and a methodology was applied to determine the nature of the problem. The case study was extremely important to reinforce the need for companies to adopt continuous improvement and the mapping of losses and waste in their process as something usual and routine, because only then, it is possible to identify and measure losses for the development of cost reduction projects with great impact on the organization’s results.