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Mitigação da Formação dos Pequenos Torrões do Açúcar Areado Amarelo
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A ocorrência de torrões no Açúcar Areado Amarelo (AAA) tornou-se um grande desvio na produção deste tipo de açúcar, devido ao aumento de reclamações por clientes de consumo final e de futuros compradores, sendo necessário a otimização da qualidade e produção deste produto. De 7 de março a 21 de abril de 2022, um pacote de AAA de 1Kg era composto por cerca de 16.8% de torrões com diâmetro superior a 2 mm. Esta situação causava o aumento do reprocessamento deste açúcar e dificuldades no seu embalamento devido à qualidade reduzida, provocando também uma diminuição na margem de negócio e competitividade da empresa, sendo necessário o desenvolvimento de um projeto Six Sigma, de modo a minimizar este desvio de produtividade e qualidade, utilizando a metodologia DMAIC. Através de análises estatísticas, como regressões múltiplas lineares, verificou-se que a elevada temperatura do AAA durante o sistema de transporte e a sua elevada humidade são a causa-raiz da formação dos torrões, pois estas condições promovem o fenómeno de caking. Este é definido como a aglomeração de cristais de açúcar, por consequência de condições de armazenamento, como a humidade relativa e a temperatura, formando os torrões. Foram implementadas um conjunto de ações, de modo a reverter as condições de caking, e observouse melhorias consideráveis na mitigação da formação dos torrões de AAA. Afirma-se, com 99% de confiança, que a quantidade média de torrões de AAA por pacote diminuiu para 8.8%, ou seja, houve uma redução de cerca de 48%. Portanto, foi possível mitigar a formação de torrões de AAA, aumentando deste modo a qualidade deste produto e, consequentemente, diminuindo a quantidade de AAA reciclado, sendo assim otimizada a produção deste açúcar.
The occurrence of lumps in Areado Sugar (AAA) has become a major deviation in the production of this type of sugar, due to the increase in complaints by customers of final consumption and future buyers, being necessary the optimization of the quality and production of this product. From March 7th to April 21st of 2022, a 1 Kg pack of AAA consisted of about 16.8% of lumps with a diameter greater than 2 mm. This situation caused the increased reprocessing of this sugar and difficulties in its packaging due to reduced quality, also causing a decrease in the company’s business margin and competitiveness, requiring the development of a Six Sigma project in order to minimize this deviation in productivity and quality, using the DMAIC methodology. Through statistical analysis, such as multiple linear regressions, it was found that the high temperature of the AAA during the conveying system and high moisture are the root cause of the formation of the lumps, because these conditions promote the caking of sugar. This phenomenon is defined as the agglomeration of sugar crystals, as a result of storage conditions such as relative humidity and temperature, forming the lumps. A set of actions were implemented to reverse the caking conditions, and considerable improvements were observed in the mitigation of the formation of AAA lumps. It is stated, with 99% confidence, that the average amount of AAA lumps per pack decreased to 8.8%, i.e., there was a reduction of about 48%. Therefore, it was possible to mitigate the formation of AAA lumps, thus increasing the quality of this product and, consequently, decreasing the amount of recycled AAA and optimizing the production of this sugar.
The occurrence of lumps in Areado Sugar (AAA) has become a major deviation in the production of this type of sugar, due to the increase in complaints by customers of final consumption and future buyers, being necessary the optimization of the quality and production of this product. From March 7th to April 21st of 2022, a 1 Kg pack of AAA consisted of about 16.8% of lumps with a diameter greater than 2 mm. This situation caused the increased reprocessing of this sugar and difficulties in its packaging due to reduced quality, also causing a decrease in the company’s business margin and competitiveness, requiring the development of a Six Sigma project in order to minimize this deviation in productivity and quality, using the DMAIC methodology. Through statistical analysis, such as multiple linear regressions, it was found that the high temperature of the AAA during the conveying system and high moisture are the root cause of the formation of the lumps, because these conditions promote the caking of sugar. This phenomenon is defined as the agglomeration of sugar crystals, as a result of storage conditions such as relative humidity and temperature, forming the lumps. A set of actions were implemented to reverse the caking conditions, and considerable improvements were observed in the mitigation of the formation of AAA lumps. It is stated, with 99% confidence, that the average amount of AAA lumps per pack decreased to 8.8%, i.e., there was a reduction of about 48%. Therefore, it was possible to mitigate the formation of AAA lumps, thus increasing the quality of this product and, consequently, decreasing the amount of recycled AAA and optimizing the production of this sugar.
Descrição
Palavras-chave
Açúcar Areado Amarelo Torrões Humidade Temperatura Caking