Análise da gestão da manutenção em uma indústria empacotadora de açúcar no município de Jequié-BA por Meio da metodologia DMAIC

Abstract

Considering the competitive scenario among companies due to the generation of new technologies to improve equipment performance, asset management in factories has become increasingly necessary. Food industries seek to adopt strategies to increase productivity and machinery availability, as well as reduce maintenance costs. This work aims to analyze maintenance management in a sugar packaging industry in the city of Jequié (BA), implementing maintenance planning and control (PCM) techniques. The research is exploratory and the applied methodology is DMAIC, from the English Define, Measure, Analyze, Improve, Control, in order to implement the continuous improvement process. The selected research method consists of the case study. In the literature review stage, Google Scholar was used to survey articles, scientific papers, and theses on the scope of this work, between 2020 and 2024, with the purpose of verifying the most used techniques for PCM in the industry, mainly food. The brainwriting methodology was applied with the participation of a multidisciplinary team to prepare and apply a checklist on site, with the purpose of gathering information on maintenance management. In addition, the FMEA (Failure Mode and Effects Analysis) was completed for the machine that presented the most recurrent problems in the mentioned industry (MM-250 machine, INDUMAK brand), with the objective of evaluating the main breakdowns and technical recommendations. The statistical analysis applied to MM-250 machines is the Pareto diagram. It was found that the company does not have a preventive maintenance or lubrication plan. Another aggravating factor is the lack of an inspection checklist. This inefficient maintenance management can result in a reduction in the useful life of the machine, excessive costs with corrective maintenance, and the risk of accidents. The documents and procedures prepared in this work aim to provide basic guidelines regarding preventive maintenance to improve the management of the mentioned sector, with an approach in the structuring of PCM techniques, especially for the machine with the most recurrent history of breakdowns (MM-250). The study found a 5W2H action plan, with technical recommendations to solve the inconsistencies identified in the diagnosis, as well as the prioritization of actions through a GUT matrix proposal. Therefore, it is expected that from the implementation of the PCM techniques suggested in this work, a standardization of actions and the beginning of maintenance sector records will occur, minimizing panels and equipment failures, as well as contributing to the increase in machinery availability