Otimização do processo de empacotamento de embalagens em uma indústria de produtos químicos

Abstract

The research addresses the inefficiency of the machine responsible for assembling packaging boxes for adhesive products, representing a significant challenge in the production of a chemical products company. The analysis revealed that this operational failure negatively impacted the efficiency of the production line, necessitating manual packaging and increasing the time required to complete the task. This inefficiency not only compromised the operation but also resulted in a reduction in production capacity, an increased risk of human errors in manual packaging, and potential damage to products. The need to reallocate labor for manual packaging generated additional costs for the company. In this scenario, it became imperative to address and resolve the problem to optimize the efficiency of the production process. The implementation of improvements in the packaging box assembly machine became a strategic priority to minimize negative impacts on production. To effectively deal with inefficiencies, the company applied the PDCA (Plan, Do, Check, Act) method, a recognized tool for improvement management. The improvement team conducted a detailed data collection using the 5W1H tool to fully understand the problem. An initial countermeasure was adopted, adding an operator for manual box assembly while seeking a more comprehensive solution. The Ishikawa Diagram was used to map possible causes of inefficiency, including materials, processes, equipment, labor, and the environment. The Five Whys technique was applied to identify underlying root causes. Based on the identified causes, an action plan was developed, highlighting two crucial actions. A control plan was established to prevent recurrences of the problem.The results demonstrated significant improvements in the assembly process, allowing for the strategic reallocation of operators and increasing overall efficiency. The project's success underscores the effectiveness of quality tools in resolving operational challenges and emphasizes the importance of integrating quality practices into continuous improvement projects for operational excellence.