APLICAÇÃO DE FERRAMENTAS DA QUALIDADE EM UMA EMPRESA DE PRODUTOS AUTOMOTIVOS

Abstract

The present work aimed to propose improvements in the filling process of 100ml products on the "line 2" of an automotive products factory, in order to meet specification limits and achieve a Cpk of 1.33. To identify the root cause of the problem, the steps of the PDCA cycle were followed, specifically the planning phase (Plan), using quality tools such as brainstorming, Ishikawa diagram, prioritization matrix, 5 whys, and 5W2H. The procedures revealed that the main cause of the process's inability to meet specification limits is the variation in filling at each nozzle. Other probable causes include filling not in accordance with the machine's design and the accumulation of dirt in the nozzle screens, as well as the generation of air bubbles inside the filling nozzles. Based on these findings, eight improvements were proposed: (i) Develop a work instruction** for restarting production after a pause; (ii) Conduct an economic feasibility study for the acquisition of a machine suitable for all products on line 2; (iii) Create a work instruction to guide operators in cleaning the nozzle screens; (iv) Complement the Gemba board with work instructions to facilitate access; (v) Create a work instruction for visual inspection of the piston seals; (vi) Review the preventive maintenance plan for line 2; (vii) Update the DCSG 05 table, which configures the panel of the line 2 filling machine; e (viii) Develop a work instruction for mechanically configuring the machine's pistons. The proposed improvements are essential for the filling process of 100ml products on "line 2" to meet the desired specification limits and achieve a Cpk of 1.33. It is recommended that future studies continue with the subsequent stages of the PDCA cycle, based on the planning carried out in this work. In this way, it will be possible to continuously improve the filling process, ensuring quality and efficiency in production.