Aplicação da metodologia DMAIC na redução do stock de bens alimentares. Caso de estudo na Nestlé

Dissertação para obtenção do Grau de Mestre em Engenharia e Gestão Industrial

Improvement of Operational Efficiency effectiveness (OEE) using Six Sigma DMAIC Methodology — Case Bottomer line AD2378

Overall Equipment Effectiveness (OEE) is the key metric of operational excellence. OEE monitors the actual performance of equipment relative to its performance capabilities under optimal manufacturing conditions. It looks at the entire manufacturing environment measuring, in addition to the equipment availability, the production efficiency while the equipment is available to run products, as well as the efficiency loss that results from scrap, rework, and yield losses. The analysis of the OEE provides improvement opportunities for the operation. One of the tools used for OEE improvement is Six Sigma DMAIC methodology which is a set of practices originally developed to improve processes by eliminating defects. It asserts the continuous efforts to reduce variation in process outputs as key to business success, as well as the possibility of measurement, analysis, improvement and control of manufacturing and business processes. In the case of the Bottomer line AD2378 in Papsac Maghreb Casablanca plant, the OEE figures reached 48.65 %, which is below the accepted OEE group performance. This required immediate actions to achieve OEE improvement. This Master thesis focuses on the application of Six Sigma DMAIC methodology in the OEE improvement on the Bottomer Line AD2378 in Papsac Maghreb Casablanca plant. First, the Six Sigma DMAIC and OEE usage in operation measurement will be discussed. Afterwards, the different DMAIC phases will allow the identification of improvement focus, the identification of OEE low performance causes and the design of improvement solutions. These will be implemented to allow further tracking of improvement impact on the plant operations.

Implementação de um projeto de melhorias em um processo de reação química em batelada utilizando o método DMAIC

Esta dissertação apresenta a implementação das etapas do método DMAIC (Definir, Medir, Analisar, Melhorar e Controlar) no desenvolvimento de um projeto Seis Sigma em uma indústria petroquímica. O objetivo do projeto Seis Sigma foi reduzir a variabilidade de uma característica de qualidade crítica para o cliente e diminuir a dispersão dos tempos de reação entre as bateladas na produção de elastômeros. Neste trabalho são apresentadas as principais técnicas e ferramentas estatísticas utilizadas nas cinco etapas do método DMAIC, tais como brainstorming, mapeamento de processo, diagrama de causa e efeito, matriz da causa e efeito, gráfico de Pareto, FMEA e análise de regressão linear múltipla. A pesquisa desenvolvida de forma participativa, através da interação entre o pesquisador e os especialistas do processo, evidenciou a importância do conhecimento técnico do processo e um bom planejamento para a aquisição dos dados, como pontos importantes para a realização de um projeto de melhoria bem sucedido. O estudo apontou ainda, deficiências no sistema de controle de temperatura do reator, no sistema de medição para a característica de qualidade viscosidade Mooney e no sistema de dosagem dos insumos.

Uma aplicação do planejamento de experimentos e carta de controle em uma indústria de cosmésticos: ciclo DMAIC

Pós-graduação em Engenharia de Produção - FEB

Aplicação do DMAIC em uma indústria farmacêutica

In an industry, being a big one or small one, the process improvement is always a focus for it to increase in the market. The improvement, if searched in a simple meaning, brings the unique meaning of change to better. However the meaning of process improvement can take much more than a superficial point of view. Kaizen, Process improvement, Continuous improvement, they are some denotations much more comprehensive of a such a term carried of so many meanings. A good concept of improvement if to search inside processes a more appropriate way, a more succinct, a more economic way to realize it. The idea is to make the process in a better way. In this graduation thesis, there will be presented a process improvement realized in a Vale do Paraíba company. For that, it was used the DMAIC to obtain, measure and control the process improvement. It should be noted that the goal is to present and discuss a process improvement

Identificação de causas especiais no processo que aumentam a ocorrência de poro na solda de tubos de aço: aplicação etapas definir, medir e analisar do DMAIC

This work covers the methodology Six Sigma with the application of the steps Define, Measure and Analyze a company of steel tubes, with the objective of identify special causes in the process that drives the creation of the pore defect in the solder. It is highlighted the fact that this work is the base of an continuous upgrade project that aims in eliminating the occurrence of this defect. The motivation is given to the necessity of improving the productivity of the factory, considering that the defect occurs at random and your causes are unknown. This way, it was defined that the problem to analyze, measured the capability of the process in DPMO and analyzed with the aid of graph by attribute P. The results show the process that present special cases, as well as the process considered ideal, This way it was stated that in this work, the processes destabilized and the controlled, allowing a comparison of the characteristics for the elaboration of concise action plans to eliminate the defect. The project must follow the steps Upgrade and control the methodology Six Sigma, in order to ensure success in his execution, aiming to amplify the competitive edge of the business

Estudo de caso: aplicação do método DMAIC-White Belt- na redução de latas amassadas em uma produção de leite em pó

This work consists of the implementation of the steps Define, Measure , Analyze , Improve and Control ( DMAIC ) to develop a Six Sigma project in an industry the food industry. The objective was to demonstrate a potential for reducing the occurrence of crushed cans in potting milk powder industry in a White Belt project. The food industry accounts for about 9 % of Brazil's gross domestic product ( GDP ), generating thousands of jobs . Among the major sectors of the food industry is the manufacturing sector of milk , occupies approximately 10 % of the total turnover of the food industry . Brazil is considered today one of the eight largest producers of milk powder in the world. The milk powder is packed , mostly for aluminum cans that are lined internally with varnishes and other materials to protect the milk of metals from aluminum. When the cans are dented food protection is compromised and may lead ingestion causing dis-eases such as botulism. Aiming to solve the problem of dented cans methodology was used as a case study with a quantitative approach through the DMAIC method. Some quality tools used in each step of the project as brainstorming , cause and effect diagram , flowchart , ef-fort and impact matrix, 5W1H , among other Pareto diagram is presented . A survey about the disposal of cans in the company verifying a mean loss and, from this histor-ical , a goal loss was calculated was performed . With the target set we calculated the annual saving design . During application of DMAIC was found that the highest rate of loss occurred in transportation between the factory and the factory that fills cans milk . Several actions were taken to resolve problems that resulted in dented cans and the first two months of phase control it was found that the smaller losses calculated target resulting in a saving for the company. The short time of implementa-tion of the Improve phase did not allow a more detailed a ...

Projeto DMAIC com ferramentas six sigma para redução de custos logísticos de uma multinacional

This work has a focus on project execution DMAIC ( Define Measure Analyze Implement Control) , using the statistical and quality tools to identify , analyze and implement improvements in a given process in order to reduce costs telephony transport of a multinational consumer goods . The multinational consumer goods to be studied has outsourced carriers who perform the distribution of its products , which may lead them straight to their factories or one of its distribution centers to the points of sale ( supermarkets , bakeries , gas stations , convenience cafeterias , among others ) . Whenever there is an unexpected situation or some problem at the time of delivery of the goods to the customer opens an occurrence , ie , the carrier responsible for contacts ( 0800 ) with the contact center company of consumer goods which in turn registers the occurrence, analyzes and sends a response action to the carrier . This work will study the problem with a high number of connections to handle occurrence , through analysis and data collection , identify improvement opportunities, implement them and monitor the results to ensure that the gain and loss reduction are sustainable

Projeto DMAIC com ferramentas Seis Sigma para redução de sucata em uma multinacional do ramo de acessórios automobilísticos

In this era of globalization, with fierce competition in the labor market, using the reduction cost strategy and resources optimization, has become a competitive advantage. In this graduation study, it will be exposed in form of case study the DMAIC project (Define Measure Analyze Improve Control) execution, using of Six Sigma's tools, statistical and quality knowledge, with intent of analyze, improve and control the processes of a selected problem, always demonstrating good practice of methodologies. In an auto parts multinational branch, It was identified a high scrap rate in one of his production lines. This work will study this problem to improve their processes and ensure that these improvements are perpetual. As a result, reached the stipulated goals, increasing Corporation's Intellectual, thereby providing a competitive advantage

Melhoria de eficiência de máquinas pela metodologia DMAIC em eventos Kaizen

In a highly competitive and globally integrated market, excellence in production processes has become a survival factor, instead of just a differential point. In this context, companies from various sectors have resorted to philosophies and techniques already established in the literature to improve the efficiency of their production processes. This paper discusses aspects and techniques used to improve the production efficiency of a multinational company that manufactures surgical devices to a global market. Through DMAIC methodology, there were found opportunities to improve machines' efficiency by OEE, an efficiency indicator, in Kaizen Events. A case study was conducted to analyze the methodology and to identify good practices and difficulties along the way

Melhoria de eficiência de máquinas pela metodologia DMAIC em eventos Kaizen

In a highly competitive and globally integrated market, excellence in production processes has become a survival factor, instead of just a differential point. In this context, companies from various sectors have resorted to philosophies and techniques already established in the literature to improve the efficiency of their production processes. This paper discusses aspects and techniques used to improve the production efficiency of a multinational company that manufactures surgical devices to a global market. Through DMAIC methodology, there were found opportunities to improve machines' efficiency by OEE, an efficiency indicator, in Kaizen Events. A case study was conducted to analyze the methodology and to identify good practices and difficulties along the way

Aplicação da metodologia DMAIC a uma linha de produção de cartão canelado

O presente trabalho resultou da realização de um estágio curricular na empresa Fábrica de Papel e Cartão da Zarrinha, S.A.. O trabalho incide sobre a aplicação da metodologia DMAIC da abordagem Seis-Sigma a uma linha de produção de cartão canelado, mais especificamente a um tipo de não conformidade do mesmo, denominado por cartão com Warp (ou cartão com empeno). Através desta aplicação, foi possível encontrar as principais causas-raíz do problema em questão e delinear possíveis ações de melhoria para solucionar o mesmo. Durante a implementação desta metodologia foram utilizadas várias ferramentas de qualidade que permitiram uma melhor gestão e tratamento da informação de forma a agilizar alguns processos também como a comunicação interna. Sob a forma de resultados, além de se testemunhar a diminuição de placas e embalagens de cartão com warp, conseguiu-se também a sensibilização dos vários departamentos para a problemática em questão e, principalmente, para a utilização e consciencialização da metodologia Seis-Sigma e dos seus benefícios.

"Seis sigma": uma nova cultura empresarial

Existe uma miríade de ferramentas para a gestão da qualidade. A grande maioria apareceu no meio industrial, e algumas ultrapassaram barreiras, chegando a todas as áreas de negócio. O processo Seis Sigma é uma ferramenta que se destacou pela sua versatilidade e eficácia, e alcançou uma grande notoriedade na indústria fabril. O discente teve a oportunidade de contactar com o processo Seis Sigma, que evidenciou a sua validade, como ferramenta poderosa em qualquer área de negócio. Baseado nesse trabalho, pretende-se demonstrar a mais-valia que esta ferramenta apresenta, e que, com empenho e dedicação, todos podem usar. Os objectivos deste trabalho são: • Identificar o valor superior numa empresa do ramo automóvel na implementação de um processo Seis Sigma numa área de BackOffice; • Verificar se após o fim do projecto Seis Sigma, as medidas implementadas continuam a produzir efeitos. Metodologia usada para a execução deste trabalho • O discente, com a função de Green Belt, foi o responsável pela implementação de um projecto Seis Sigma. No seguimento do que já havia sido efectuado no projecto Seis Sigma, este trabalho usou a ferramenta DMAIC (ver p.5) como metodologia para a sua execução. Conclusões Ficou demonstrado com este projecto, em que o discente teve um profundo envolvimento, que a metodologia Seis Sigma ao ser aplicada num qualquer processo repetitivo de trabalho vai: • Obrigar a repensar todos os procedimentos instalados procurando todas as oportunidades demelhoria; • Criar novas ferramentas para dar solução às oportunidades encontradas; • Verificar a validade e mais-valia nas novas ferramentas e procedimentos; • Em função da constante verificação, melhorar as ferramentas e procedimentos instalados, ou criar novos procedimentos ou ferramentas; • De uma forma permanente, continuar a analisar o processo, monitorizando a qualidade e a procura de novas oportunidades de melhoria. O facto de o processo Seis Sigma obrigar a uma introspecção ao trabalho realizado, e, tornar todo o processo de melhoria sistemático, faz com que seja sempre uma mais-valia a sua aplicação, num ambiente fabril, ou de BackOffice. Ainda que o processo Seis Sigma seja terminado a dada altura, as melhorias que trouxe e as ferramentas que foram desenvolvidas para a sua execução ficam, deixando um legado de melhoria de processos, que, por si só, justificam a sua implementação.

Reengenharia de processos na indústria farmacêutica

Dissertação apresentada para obtenção do Grau de Mestre em Engenharia e Gestão Industrial pela Universidade Nova de Lisboa, Faculdade de Ciências e Tecnologia

Implementação da metodologia 6 sigma no processo de facturação

Dissertação apresentada na Faculdade de Ciências e Tecnologia da Universidade Nova de Lisboa para obtenção do grau de Mestre em Engenharia Industrial