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Estudo de Controlo e Otimização da Rejeição de Garrafas e Latas por Nível de Enchimento
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Nas linhas de enchimento de produtos líquidos, existem equipamentos de inspeção que, ao longo do processo de enchimento, verificam vários parâmetros de qualidade do produto. No caso de indústrias cervejeiras, essa inspeção averigua erros como: ausência de cápsula e rotulagem, insuficiência de pressão interna e de nível de enchimento, entre outros.
Este trabalho teve como principal objetivo implementar garrafas e latas teste de nível de enchimento e padronizar os inspetores localizados após as máquinas rotuladoras, de modo a controlar e reduzir as rejeições de recipientes por este tipo de erro, uma vez que este era o erro responsável por 50% ou mais das rejeições totais em todas as linhas.
De forma a estruturar o trabalho e a desenvolver um método para atingir os objetivos estipulados, seguiu-se uma metodologia de Lean Six Sigma, nomeadamente, a DMAIC.
Dada a inexistência de uma regra rigorosa na parametrização dos inspetores para este erro de nível de enchimento, na fase inicial de recolha de dados, verificou-se que [43-81]% dos produtos rejeitados por esse erro eram amostras cujo conteúdo efetivo estava dentro dos limites da legalidade presentes no Decreto de Lei 199/2008 e na Portaria nº 374/2023.
Assim, desenvolveram-se 3 procedimentos de criação de garrafas e latas teste, um para as garrafas retornáveis, outro para garrafas de tara perdida e finalmente um para as latas, tendo em conta procedimentos internos da empresa, a legislação portuguesa referente a conteúdo efetivo de produtos pré-embalados e as boas práticas, de forma a padronizar o método de rejeição de nível de enchimento dos inspetores e a evitar o desperdício de produtos conformes.
Estudou-se uma melhoria do processo de enchimento na redução do desvio nominal por excesso num formato de latas e, para tal, foi seguida uma ferramenta da filosofia Lean, o Kaizen.
Por fim, recolheram-se os resultados das melhorias implementadas e verificou-se que a nova parametrização dos inspetores contribuiu para uma redução de 72% das rejeições por nível insuficiente nas 5 linhas estudadas. Relativamente à segunda oportunidade de melhoria, registou-se uma redução de 52% do seu desvio nominal de enchimento.
Deste modo, poder-se-á afirmar que este trabalho destacou a importância do controlo de processo na indústria, contribuindo para a redução dos impactos económicos e ambientais negativos próprios da mesma.
In liquid product filling lines, there are inspection equipments that check various product quality parameters throughout the filling process. In the case of breweries, this inspection checks for errors such as the absence of crown corks and labeling, insufficient internal pressure and filling level, among others. The main goal of this work was to implement test bottles and cans for fill height check and standardize the inspectors located after the labelling machines, to control and reduce container rejections due to this type of error, since on all lines, this was the error responsible for 50% or more of total rejections. With the aim of structuring the work and develop a method to achieve the stipulated purposes, a Lean Six Sigma methodology was followed, namely DMAIC. Given the lack of a strict rule in the inspectors' parameterization for this filling level error, in the initial data collection phase, it was found that [43-81]% of the products rejected for this error were samples whose net content was within the legal limits. Three procedures were developed to produce test bottles and cans, one for returnable bottles, another for one-way bottles and finally one for cans, considering the company's internal procedures, Portuguese legislation on the net content of pre-packaged products and best practices, in order to standardize the inspectors' method of rejecting fill levels and avoid wasting compliant products. Next, an improvement in the filling process was studied to reduce the nominal deviation due to overfill in a can format, using a tool from the lean philosophy, Kaizen. Finally, the results of the improvements implemented were collected and it was found that the new parameterization of the inspectors contributed to a 72% reduction in rejections due to insufficient filling level on the 5 lines studied. Regarding the second improvement, there was a 52% reduction in the nominal filling deviation. Thus, it can be said that this work has highlighted the importance of process control in the industry, helping to reduce the negative economic and environmental impacts of the industry.
In liquid product filling lines, there are inspection equipments that check various product quality parameters throughout the filling process. In the case of breweries, this inspection checks for errors such as the absence of crown corks and labeling, insufficient internal pressure and filling level, among others. The main goal of this work was to implement test bottles and cans for fill height check and standardize the inspectors located after the labelling machines, to control and reduce container rejections due to this type of error, since on all lines, this was the error responsible for 50% or more of total rejections. With the aim of structuring the work and develop a method to achieve the stipulated purposes, a Lean Six Sigma methodology was followed, namely DMAIC. Given the lack of a strict rule in the inspectors' parameterization for this filling level error, in the initial data collection phase, it was found that [43-81]% of the products rejected for this error were samples whose net content was within the legal limits. Three procedures were developed to produce test bottles and cans, one for returnable bottles, another for one-way bottles and finally one for cans, considering the company's internal procedures, Portuguese legislation on the net content of pre-packaged products and best practices, in order to standardize the inspectors' method of rejecting fill levels and avoid wasting compliant products. Next, an improvement in the filling process was studied to reduce the nominal deviation due to overfill in a can format, using a tool from the lean philosophy, Kaizen. Finally, the results of the improvements implemented were collected and it was found that the new parameterization of the inspectors contributed to a 72% reduction in rejections due to insufficient filling level on the 5 lines studied. Regarding the second improvement, there was a 52% reduction in the nominal filling deviation. Thus, it can be said that this work has highlighted the importance of process control in the industry, helping to reduce the negative economic and environmental impacts of the industry.
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Palavras-chave
Garrafas e latas teste inspetores rejeições por nível de enchimento controlo DMAIC Kaizen