Avaliação do desperdício no processo produtivo de embalagens Doy Pack: possíveis causas e soluções

Abstract

Flexible plastic packaging has revolutionized the packaging sector due to its versatility, greater protection, barrier properties, and transparency, which have enabled its application in the most different industry segments. The manufacturing of these packages is relatively complex, depending on the type, and involves variables ranging from the transformation process of the raw material to the product ready for commercialization, and waste and losses are frequent in the process. Therefore, before reaching the final consumer, these packages go through several tests aiming to ensure the quality, protection of the filled product and avoid losses. Among these tests is the Coefficient of Friction (COF), which measures the friction force when sliding a material over a specific surface, and the determination of film thickness and grammage, that can be decisive in application and the choice of material. In this context, the present work aimed to identify and evaluate the possible causes of waste in the production process of Doy Pack packaging in a company in the metropolitan region of Recife and based on this data, develop an action plan to reduce these losses. To this purpose, one of the most important sectors of the company, the filling sector, was monitored, analyzing 30 samples (spools) during a 40 days period in the afternoon shift. During this period, the COF was determined, before and after filling, grammage and thickness in random samples of the films also collected in the sector under analysis were determined. Finally, an action plan was developed to help reduce losses. According to the numerical results collected on the production line, it was possible to observe that the pre-filling friction coefficient was generally in the range required in the company's standard procedure, and that after going through the filling process, this coefficient increased, hindering the sliding of the films on the reels, and causing losses. Therefore, it was observed the need for constant control of the friction coefficient, since it, being in compliance, guarantees the proper sliding of the films for Doy Pack packaging, the lower the COF, the easier the films slide on the reels, facilitating production, reinforcing the importance of controlling this physical property in the plant. The thickness and grammage results were within the company's specifications, requiring no adjustments.