Aplicação da metodologia DMAIC na melhoria contínua dos quality gates de uma linha de produção de máquinas pesadas

Abstract

To be able to survive the competition, large companies need to develop and innovate the quality process to guarantee a well-defined product inspection, with quality gates that can internally validate the product and prevent non-conformities. In the search for continuous improvement, this project used quality tools and the DMAIC methodology to improve the quality gates process in the heavy machinery production line. Given this, the 5 steps of DMAIC were developed – define, measure, analyze, improve and control, starting with the development of the Project chart and SIPOC (Supplier, Input, Process, Output, Customer), to understand the project’s scope. Data collection and process mapping were then carried out to analyze and define the root causes of the problem, using the Ishikawa Diagram, 5 Whys Analysis and the Pareto Diagram. In the fourth step, the solution was implemented and the schedule, Gantt Chart and 5W2H (What, Why, Who, Where, When, How, How much) were created. In the last stage, control of the implemented solution was carried out through KPIs (Key Performance Indicator), updating the process map and providing new standard works. Finally, the project highlights the results of the improvement with a 20% reduction in post-line process time and labor-related expenses, a 1400L reduction in fuel consumption per month and, consequently, a reduction in gas emissions. Carbon dioxide at approximately 45 million tons.