Uso de ferramentas de qualidade na redução de refugo

Abstract

This final course project focused on applying quality management methodologies and tools to address a recurring failure in a critical component faced by an automotive parts industry in 2023, which led to financial losses of approximately R$ 230,000.00 due to defective parts. The study emphasized the importance of identifying the root cause and developing effective strategies to resolve this issue, drawing on the principles of renowned quality experts such as Juran, Crosby, Deming, Ishikawa, and Feigenbaum. The objectives included utilizing quality tools like Ishikawa diagrams, Pareto charts, the A3 methodology, and the why-why analysis to deeply investigate failure causes, prioritize key factors, design a structured action plan, and implement effective corrective measures. These efforts were evaluated through performance indicators, such as reductions in scrap rates and improvements in product quality, which proved essential to the project’s success. Notable results included a failure reduction of over 60% during certain weeks through low-cost measures like manual mold drying and the dissemination of best practices among operators. This translated into a projected cost reduction of R$ 82,621.60 in 2024, representing a 36% decrease in scrap-related expenses compared to the previous year. Thus, this project not only addresses a specific operational challenge but also contributes to the continuous improvement of industrial processes, strengthening the company’s market position and ensuring its long-term sustainability. By applying proven quality management principles, this study establishes a solid foundation for operational excellence and ongoing customer satisfaction.