Application of the six sigma methodology and use of the dmaic method to reduce the loss rate of aluminium cans in a beverage industry to reduce operational costs: case study: latax refrigerantes ltda

Introduction: Six Sigma is an internationally recognized tool widely used in the identification and implementation of improvements in internal processes of an organization, aiming to obtain lower operating costs and, consequently, increase profit margins. During the application of this tool it is necessary to follow a defined sequence of steps and to establish quantified objectives. Objective: This study demonstrates how the application of the tool can assist in reducing operational costs by reducing losses of cans in the production process through cause analysis and implementation of action plans in a production line of soft drinks in aluminum cans in a beverage industry. Methodology: In the application of this study, steps of the DMAIC methodology were followed, where statistics tools were used to DEFINE the problems and identify the improvements, MEASURE during the phases of getting results, ANALYZE the collected data into useful information for decision making, IMPLEMENT the actions proposed in an action plan based on the previous steps and finally CONTROL the processes so that continuous improvement is a living cycle within the institution. Result/Discussion: The six sigma team of this project, applying VOC - Voice of Customer, Snake Diagram and SIPOC methodologies, could interact with internal customers about the soft drink bottling processes in aluminium cans, as well as the other processes that interact among themselves and how this industrialization process is inserted in the context of the organization as a whole. Conclusion: After the full implementation of the actions proposed by the six sigma team of this project, the objective was met. In comparison with the previous measured period, the analyzed process reduced the average percentage of can losses from 0.53% to 0.26% after the implemented actions. Thus, the financial contribution of the project to the company was an average annual operating cost reduction on aluminum can waste from $13,596 to $6,670, resulting in a loss reduction of $6,926 for the company.