Estudo comparativo entre as ferramentas PDCA e DMAIC aplicadas a qualidade do setor de tecelagem

Abstract

The textile industry is one of the most prominent sectors in the Brazilian economy, creating millions of jobs, specifically in the state of Rio Grande do Norte, which has a significant contribution to the PIB. However, the industry has been facing challenges such as foreign competition, the Covid-19 pandemic, and raw material price instability. So, as alternatives, the search for quality, efficiency, and technological innovation are the sector's reaction mechanisms. Management tools, such as Lean Manufacturing and Six Sigma, have been adopted to improve the performance and efficiency of industrial processes. This paper aims to apply the DMAIC and PDCA quality tools to analyze and reduce defects in weft and soft yarn, respectively, in a textile industry in the state of Rio Grande do Norte. The methodology applied in these tools presents a lot of similarity, including the Ishikawa diagram, action plans and Pareto diagram, for monitoring the evolution of the projects. Several stages of the textile industrial process were analyzed to identify the root causes of the defects studied, such as operational failure, lack of maintenance frequency and gaps in the operational procedure that resulted in reduced quality. The implementation of the quality tools made it possible to analyze the PDCA cycle, which provides a 62% reduction in costs with the soft wire defect, through a simple and effective project, while DMAIC offers a more robust and detailed structure for projects, meeting the needs of more in-depth customer studies with a reduction in the defect footage of 65%. The methodologies make it possible to meet the established objectives, such as the reduction in the size of the analyzed defects, reduction in second quality costs, and improvement in the delivery of the production process. The methodologies make it possible to meet the established objectives, such as the reduction of the analyzed defect metrics, reduction in second quality costs, and improvement in the delivery of the production process.