Aplicação da metodologia Lean manufacturing para diminuição de desperdícios em uma indústria de suco de laranja

Abstract

This paper presents the application of Lean Manufacturing principles and methods in the context of an orange juice industry, aiming to identify and reduce waste while increasing operational efficiency. The study is justified by the growing need for food industries to enhance their competitiveness through the elimination of non-value-added activities. The methodological approach was structured using the DMAIC cycle, with emphasis on the define and measure phases. In the define phase, tools such as SIPOC, requirement trees, and Y’s stratification were used to delimit the focus of analysis. In the measure phase, detailed mapping of processes and operational flows was conducted, including comparative yield measurements between laboratory and actual production. The theoretical framework covered the foundations of lean production, the seven lean wastes, and tools such as 5S, kaizen, kanban, flowcharts, 5W2H, and gemba walk, all aligned with the observed industrial reality. The study also provides a comprehensive description of the macroprocesses of orange juice production, from fruit reception to bottling and refrigeration. The results revealed actionable opportunities that can be addressed in the subsequent stages of the DMAIC cycle, contributing to increased productivity, process standardization, and loss reduction. It is concluded that adopting Lean philosophy is not only feasible but highly recommended for the sector, due to its methodological robustness and its positive impact on continuous improvement culture and overall operational performance.