Aplicação do Ciclo PDCA para Redução do Indicador de Perdas em uma Fábrica de Têmpera de Vidro em Mossoró-RN

Abstract

The continuous pursuit of industrial process optimization is directly linked to the need to reduce waste and achieve better operational and financial results. In the glass processing sector, efficiency is rigorously measured by the ability to minimize raw material loss during transformation stages. In this context, the problem addressed in this research concerns the high operational loss indicator at a glass tempering factory located in the municipality of MossoróRN, Brazil. Based on a historical analysis of the first five months of 2025, the organization presented an average loss rate of 5.63% relative to total production, falling short of the strategic target of 3% and operating above acceptable industry limits. Therefore, a continuous improvement project grounded in the PDCA Cycle methodology (Plan-Do-Check-Act) was implemented to mitigate this indicator. The investigation of the production process relied on quality tools such as Stratification and the Ishikawa Diagram, which revealed that the root cause of waste was concentrated in the Grinding and Furnace sectors, driven by the absence of standardization and control routines. Corrective and preventive actions were developed through structured action plans, focusing on the implementation of daily inspection checklists, operational training, and the formalization of preventive maintenance. The application took place in two intervention cycles. The first cycle reduced the indicator from 5.63% to 3.42%, representing a 39.25% reduction. With the correction of deviations and the strengthening of managerial monitoring, the second cycle enabled the company to reach a breakage rate of 2.20% in January 2026, representing a total reduction of 60.92% from the beginning of the project to its conclusion, surpassing the established target and proving the method's effectiveness in stabilizing processes and perpetuating good practices on the shop floor.