Redução de perdas por aparas: um estudo de caso em uma indústria de plásticos flexíveis.

Abstract

Due to the growth of the flexible plastics manufacturing sector, the high competitiveness in this area is notorious, so companies want to have high production, with lower costs and minimal waste, in addition to manufacturing quality products that satisfy the customers. With the use of process and quality management tools, it is possible to achieve continuous improvement and reduce waste, identify the root cause of losses, and find ways to reduce their incidence. Therefore, the present study aims to minimize losses due to shavings in a flexible plastics industry located in the State of Paraíba. To this end, the ABC Curve was constructed to determine which causes result in the largest quantity of scraps in the industry and, thus, prioritize them. Then, improvements were proposed based on Kanban, Poka-Yoke, Standard Operating Procedure, 5W1H. With the results, it was observed that, in 18 months, the company had a loss of 1,112,113.61 reais due to losses due to trimmings, which represents a significant value for the organization. Furthermore, it was detected that the main causes of losses in the process, corresponding to Class A of the ABC curve, are extrusion, setup, and order change failures. Based on the analysis and prioritization of losses, improvements were indicated that will result in a more optimized process with less waste.