Redução dos índices de perda de lata e extrato em uma indústria de bebidas

Abstract

In the current context, the continuous improvement of the industrial processes on the shop floor is not just a matter of reducing costs or losses, but also a way of creating an environment that engages coworkers and values providing new knowledge and tasks day after day. This study demonstrates the application of continuous improvement methodologies and tools to reduce Can and Extract losses on a packaging shop floor at a local industry. Some of these methodologies are called Value Stream Mapping, Unified Problem Solving, Root Cause Failure Analysis and Kaizen Teams and they were applied with the help from the machine’s operators and their supervisors. Two Kaizen Teams were created, one with focus on Can loss and the other on the Extract loss, both following the same already defined steps and establishing quantified goals, as is already expected from a team of its nature. The root cause of every loss was investigated and corrective actions were established so these losses could be reduced as much as possible. After this, all the goals were achieved. In comparison with the previous measured period, the analyzed process reduced the average percentage of can losses from 1,02% to 0,36% and the average percentage of extract losses from 1,65% to 0,44% after the implemented actions.