Otimização do índice de perda de latas (IPL) e consumo de CO₂ em linhas de produção de cervejaria: um estudo de caso aplicado

Abstract

The brewing industry constantly faces challenges to increase operational efficiency and adopt more sustainable practices. This case study investigates the optimization of the Can Loss Index (CLI) and the reduction of carbon dioxide (CO₂) consumption in a canning line of a brewery located in Manaus, Amazonas, Brazil. The research was motivated by the need to reduce costs, minimize waste, and align with environmental sustainability goals. The adopted methodology was based on the Method of Analysis and Problem Solving (MASP), using quality tools and data collection before and after the intervention, over two 30-day periods. The main action was the installation of a manual CO₂ regulation bar on the filler, replacing the previous adjustment system. The results were significant: CO₂ consumption dropped by 81.5%, CLI was reduced to 0.11%, and productivity reached 99.7% of nominal capacity. The study demonstrates that low-cost interventions, when well applied, can deliver substantial gains in efficiency, sustainability, and organizational culture.