Proposta para análise de causa raiz de quebras de máquinas integrada ao método A3 em uma indústria farmacêutica

Abstract

This study presents a proposed work procedure for applying Root Cause Analysis (RCA) integrated with the A3 method in a multinational pharmaceutical company. The organization already has a structured maintenance department, with subdivisions by area, an implemented SAP-PM system for managing service orders, and performance indicators such as MTBF (Mean Time Between Failures) and equipment availability. Additionally, it uses an A3 report form that incorporates tools like 5W2H, Ishikawa diagram, and the 5 Whys. However, there is no formalized procedure that defines clear criteria for applying RCA, nor specific training on its use. In response to this gap, this research developed a standardized procedure that establishes criteria for identifying which failures should be investigated, based on asset criticality and operational indicators. The proposal also structures the investigation stages, defines deadlines, establishes the analysis team, and guides the appropriate use of the tools already included in the company’s A3 form. The adopted methodology was qualitative, with an explanatory approach and action research strategy, involving field observations, internal document analysis, and interviews with maintenance personnel. As a result of this work, a structured and context-appropriate procedure was developed for RCA application. The proposed solution contributes to the standardization of analyses, greater assertiveness in identifying root causes, improved asset reliability, enhanced maintenance performance indicators, technical training of personnel, and the strengthening of a culture of continuous improvement.