Avaliação de eficácia de um projeto pdca implementado por equipes de melhoria contínua: redução do indicador de aparas em uma indústria de poliestireno extrudado (xps)

Abstract

This study aimed to evaluate the effectiveness of the PDCA (Plan, Do, Check, Act) methodology in conducting a continuous improvement project focused on reducing the trim generation indicator in an extruded polystyrene (XPS) industry. Excessive trim represents a recurring issue in this type of production process, as it is directly associated with raw material waste, increased operational costs, and environmental impacts resulting from improper disposal. The research was carried out through a case study in the thermoforming sector, where operational routines were monitored, historical production records were analyzed, and the process performance was compared before and after the implementation of a practical solution: the installation of specific supports for reels. The PDCA methodology was applied in all its stages, enabling the identification of the root cause of the problem, the development of the action plan, the execution of the proposed improvements, the verification of the results, and the standardization of the new procedure. The results showed a significant reduction in the trim indicator, confirming the effectiveness of the intervention. In addition to the quantitative impact on loss reduction, a qualitative improvement was observed in team engagement, as employees adopted a more analytical and proactive attitude toward problem-solving. It is concluded that the application of the PDCA cycle proved to be a practical, systematic, and efficient tool not only for achieving operational and economic gains but also for strengthening the culture of continuous improvement and sustainability within the production environment.