Uso da engenharia de processos e ferramentas Lean Six Sigma na melhoria dos resultados do setor de fundição em uma fábrica de médio porte

Abstract

The desire to use a lean manufacturing methodology affects medium-sized factories. The project’s focus factory produces battery hulls by plastic injection and fits as a medium-sized industry. Wishing to improve the performance and quality of the foundry sector, results were lower than expected for previous investments made, the project sought as premises, to use Lean Six Sigma tools and concepts to improve results and reduce the rate of defects. To do this, analyze the current state, detecting losses and acting to remove sources of uncertainty regarding the information. Implementing the internal production and logistics system together with the best data collection favored the team to identify and act on the root causes of the defect with the greatest impact on production. Thus, the use of methodologies and fixation of factory knowledge ends up generating tangible and intangible benefits for the entire company, such as gaining space, confidence in quality and greater profitability. Creating the pulled flow, it was possible for the sector to leave the dependence on the PCP to schedule production and the batches sent changed from 12 tons per week to small batches of at least 120 kg per hour according to demand. The gains in product quality reflected in the reduction of the non-conformity rate, generating estimated gains of R$ 2.000,00 per day of production, approximately R$ 500.000,00 per year, with increased reliability and performance in the client sectors, due to the reduction in the need for conferences of non-conformities and movement of refuse.