Execução de um projeto Lean Seis Sigma para redução de desperdícios em linha de envase de iogurtes de uma indústria de laticínios: um estudo de caso

Abstract

The reduction of packaging losses in the food industry represents a significant challenge to the sector's sustainability and competitiveness. This study focused on packaging losses in the production process of a dairy industry, a sector of notable importance to the Brazilian economy. During the production stages, waste inherent to the industrial process is generated, which significantly impacts the environment. In the company studied, located in the western region of the state of Paraná, a considerable amount of packaging loss was identified on the IMAAJ 68 thermoforming filling line. Given this scenario, the main objective of this work was the execution of a continuous improvement project based on the Lean Six Sigma methodology, using the DMAIC cycle, aiming to reduce packaging losses on this filling line. The project resulted in a 57.03% reduction in packaging losses, with projected savings exceeding R$ 126,000.00 per year, demonstrating the effectiveness of the adopted method in promoting operational and financial improvements. To achieve this result, the steps of the DMAIC cycle were followed: detailed assessment of losses in the thermoforming process, data collection and analysis, identification of root causes, and development of an action plan. The reduction achieved not only minimized waste but also created opportunities for proposing improvements in other areas of the organization, with the prospect of gradually implementing an operational management system without the need for significant investments. This strategic approach allowed for the efficient integration of changes into the existing process, delivering concrete results in the short and medium term. The use of Lean tools in this study contributed not only to mitigating packaging losses but also to strengthening the company’s sustainability and operational efficiency.