ADOPTING PDCA TO LOSS REDUCTION: A CASE STUDY IN A FOOD INDUSTRY IN SOUTHERN BRAZIL

This study presented a case study about the application of the PDCA Cycle to analyze and solve the problem of excessive losses of sauce in a process that produces frozen meals in a food industry in Southern Brazil. Through a quantitative and qualitative approach, it was demonstrated the way of implantation of PDCA in the process and its performance as a tool for continuous improvement. The amount of lost sauce was weighed for the calculation of losses as well as a survey of the status of the process indicators prior to the application of the PDCA. Through the use of quality tools, the causes of the problem and their respective solutions were defined through a plan of action. The adoption of the PDCA Cycle reduced losses of sauce by 86.75% due to improvements in the design and operation of the sauce dispensing equipment, leading to an overall improvement of the process as well as evolution in the results of all process indicators.