Aplicação da ferramenta 5S em uma usina sucroenergética

Abstract

The 5S program is a methodology that originated in Japan, focused on continuous improvement and widely used in industrial environments to promote organization, standardization, and operational efficiency. Its implementation aims to create safer, more productive, and visually manageable workspaces, contributing to stronger organizational culture and improved team performance. This study presents the practical application of the 5S program in a sugar-energy plant that belongs to a nationally operating group composed of several operational units, with a focus on the unit located in the interior of Minas Gerais, Brazil. The initiative covered the industrial, agricultural, and automotive maintenance sectors. The goal was to promote improvements in organization, cleanliness, standardization, and workplace safety, contributing to operational efficiency and strengthening the organizational culture. The methodology included mapping the plant areas, assigning responsibilities, conducting periodic audits using a standardized form, training facilitators, monitoring through physical boards, and implementing digital tools, such as an app developed in Power Apps and a monitoring dashboard built in Power BI. During implementation, challenges such as low initial engagement and delays in audits were identified and overcome through actions like internal sectorial audits, performance awards, and surprise audits. The results showed significant progress in adherence to the program, increased team engagement, standardized routines, and improvements in the physical environment of the audited areas. The digitalization of processes and visibility of results contributed to better control of activities, faster decision-making, and greater team motivation. The study concludes that a structured application of the 5S method, combined with technology and visual management, is an effective strategy for transforming the organizational environment and generating positive and sustainable impacts on the plant's operation.