Aplicação de métodos de confiabilidade e análise de falhas em equipamentos de indústria do ramo tabagista

Abstract

The industrial sector constantly faces challenges to improve efficiency, quality, and competitiveness. Companies that do not adopt effective maintenance strategies end up dealing with high costs, waste, and production losses. In the tobacco industry, where production volumes are high and equipment reliability is essential, frequent failures can directly compromise productivity and financial results. This study aimed to increase equipment availability and reduce failures in a production line within this sector, focusing on the tobacco return conveyor belt, a component that exhibited a high failure rate. The adopted solution was the Failure Mode and Effects Analysis (FMEA), a tool that allows the identification of potential issues and the definition of preventive actions. Additionally, reliability calculations and operational analyses were applied to support decision-making and measure the impact of improvements. With the implementation of the proposed actions, there was an observed reduction of approximately 58% in the frequency of component failures and an increase in estimated reliability (for 11 days of operation) from approximately 32% to 77%. Consequently, the production line began to operate for longer periods without interruptions, reducing the need for emergency repairs and making production more predictable, which resulted in a relative productivity gain of 15.2 million cigarettes in the post-implementation semester due to reduced downtime. Another important point was the shift in how the team perceived maintenance. In daily operations, operators began to notice the benefits of more structured planning, which helped prevent problems before they became critical. This engagement was essential to ensure that the implemented improvements were sustained over time and became part of the factory’s routine. This study demonstrates that investing in strategic maintenance not only prevents losses but also boosts productivity and strengthens the company’s competitiveness in the market.