Aplicação da metodologia LEAN SIX SIGMA no processo de troca de matéria prima em uma indústria de injeção de plásticos do Polo Industrial de Manaus

Abstract

Quality comprises the value that a company seeks to improve the expectations of its internal customers as well as external ones. Survival is of paramount importance for companies to be able to meet the demands of society, which over time, becomes increasingly aware. Lean six sigma is not a ready-made recipe that will be applied as standard for all companies, we must be careful that the two methodologies really interact, creating competition, can lead to the failure of the improvement project. Several experiences and the literature have been looking for a way to integrate the two present methodologies in order to have a perfect adoption of LSS. The general objective of the work is to apply the Lean Six Sigma methodology to solve a problem of changing raw material in the park in the plastic injection park of an industry in the industrial hub of Manaus. The research was carried out in a company in the motorcycle production industry sector located in Manaus. The classification in terms of means addresses, case study, bibliographical, documental. The classification regarding the purposes consists of research, exploratory, descriptive, explanatory, qualitative, quantitative. This course conclusion work aims to introduce a new concept of improvement, to contribute to the improvement methods already existing in the company and to contribute to the literature with a case study on the subject, which is still very scarce, mainly in applications. And eliminating process waste, contributing to cost reduction and optimization for the company's continuous improvement. In this context, after analyzing the insertion of the implementation of the Six Sigma method, using the DMAIC concept as the main application method with the help of the application of quality tools, a new study of the machine setup time was carried out, to evaluate the reduction in the time and thus optimizing the production process. In a second analysis, the plastic injection sector was chosen for the development of the LSS methodology. Because it is a sector considered small in relation to the entire production chain, therefore projects under development, such as the LSS, are viable. The results show that both the cleaning agent and the methodology are promising to eliminate contamination. Lean Six Sigma is an efficient methodology that can be adopted, that yields results and that the objectives outlined in this work have been achieved. By combining these two methods and using the Lean Six Sigma methodology, the company can take advantage of its process improvements. By implementing these tools intelligently, you can reduce product changes while reducing waste. The advantage of using the Lean Six Sigma method rather than using these two methods alone is that a smarter, integrated action plan can be completed to optimize workflow and production control. For example, you can include monitoring of standard deviation and certain types of waste in the same process, saving resources. For future work, a side review is recommended for injectors that inject polypropylene.