Aplicação de Ferramentas da Gestão da Qualidade para Análise de Falhas Industriais: Um Estudo de Caso em uma Usina de Açúcar e Álcool no interior do Estado de São Paulo.

Abstract

Industries are increasingly seeking to optimize their processes, minimize failures and reduce costs to be more competitive in the market. There then arises a constant need to remain operational and present as few failures as possible during the production of your products or services. Therefore, this article is a case study that aims to analyze which sectors have the longest downtime, identify the causes of industrial failures and propose an improvement solution in a sugar and alcohol plant in the interior of the state of São Paulo. Data were collected regarding the 2024 harvest, until the month of September, based on the data, quality tools such as Pareto diagram, Ishikawa diagram, “5 whys” and 5W2H were used to identify which equipment had the longest of inactivity, what are the causes and a proposal for improvement. It was noted that the Water Tube Boiler is the equipment with the longest downtime during the harvest and the most recurring problem was the rupture in the superheater pipes due to the incorrect procedure for the Boiler starting ramp. An improvement was proposed that involves operator training and a feasibility study could also be considered to automate the starting ramp process to minimize the chances of future failures.