Aplicação de DEMAIC em Kaizen para aumento de outputs: um suporte operacional para transferência de manufatura em spin-off

Abstract

The chemical industry plays a central role in modern industrial development, standing out for its ability to transform raw materials into high value-added products and for its strategic relevance in sectors such as healthcare. In this context, the production of dental supplies, particularly composite resin syringes for restorative procedures, is considered highly critical due to the operational precision, traceability, and regulatory compliance it requires. This study investigates the syringe filling process in a multinational company of the sector that, during an industrial spin-off, faced the challenge of maintaining productivity and market share despite the factory transfer and resource reallocation. The central research problem consisted of evaluating how continuous improvement methodologies could support the creation of safety stock, reducing supply disruption risks and ensuring operational stability in a transition environment. The general objective was to propose and apply an improvement strategy based on Lean Manufacturing principles, structured through the DMAIC cycle, and supported by Kaizen practices. The methodology was characterized as applied research, with a qualitative-quantitative and explanatory approach, conducted through a case study. Operational data and systematic analyses were used to identify bottlenecks and guide interventions. The results revealed weaknesses in process availability and organization, leading to the implementation of standardization, reconfiguration, and balancing actions that increased productivity and operational stability. As a consequence, the company achieved a 23% increase in monthly production volume, ensuring the formation of safety stock and the preservation of competitiveness during the factory transition. The integration of Kaizen and DMAIC, grounded in Lean principles, proved to be an effective solution to face variability and instability in spin-off contexts, reinforcing the relevance of continuous improvement as a strategic instrument for organizational resilience.