Aplicação da metodologia Seis Sigma para redução dos custos de produção em processo de sinterização contínua em uma metalúrgica multinacional

Abstract

The objective of the work is the application of the Six Sigma methodology in a multinational metallurgical sector, in the MIM component manufacturing sector, in the metallurgy sector, focusing on the control of process variables, reducing costs related to scrap by the high carbon failure mode. The work was developed following the steps of the DMAIC methodology, the first step being the definition of the topic to be addressed, structuring the work team and defining the project deliverables. In the second stage, the measurement of the problem was explored, validating the existing measurement system through the MSA tool, process mapping and studies related to process performance. In the third step, the problem analysis was carried out, identifying the potential causes of the failure mode studied, carrying out an action plan to address the correction of the potential causes of the problem and carrying out a fractional experiment project. In the last stages of improvement and verification of the actions defined in the project, the effectiveness of the actions defined in the third phase was implemented and evaluated. The result obtained in this work was the reduction of scrap rates from the improvement and control of process parameters, reducing variability, with this it was possible to reduce approximately 90% of the failure mode, generating savings for the company of BRL 2 million.