Identificação de desperdícios e proposta de melhoria no processo de inspeção de garrafas retornáveis numa indústria de bebidas

Abstract

The present study aims to identify the root causes and propose improvements throughout the production process using the principles of Lean Philosophy and its tools to reduce waste and costs in a brewery. Lean Manufacturing is a philosophy that aims to optimize operations by reducing processing time, waste, and making employees motivated and empowered. Furthermore, this philosophy aims to eliminate debris through a set of methodologies and tools that seek continuous improvement of production processes to add value to the customer. In this study, a real case is carried out in a brewery in Uberlândia/MG. The industry has highly technological machinery and employees who are willing to reduce bottle breakage throughout the process through the Lean philosophy and tools, an industry that currently has non-standard processes and equipment and employees without the necessary knowledge to perform their tasks and functions. To carry out the study and reach a conclusion, an applied research was carried out, with a qualitative approach, of a descriptive nature, with field observation. For this reason, the A3 Report tool was used to provide a better structuring of the problem and proposal for improvement, with the help of an Ishikawa Diagram to identify the root causes that generate the breakage of returnable bottles, and the action plan was proposed through of the 5W1H tool in order to eliminate waste and rework in the process. Therefore, after carrying out the study, it was possible to identify the benefits and advantages that the Lean Philosophy provides to companies both in the productive areas and in the service sectors, increasing competitiveness and reducing the company's costs.