Business Management Dynamics

Vol$\mathrm{.}11,$ No$\mathrm{.}07,$ June $2022,$ pp$\mathrm{.}01-19$

$$Society for Business and Management Dynamics

Proposal of Cost Reduction in the Production Process of Soft Drinks Concentrate from

Tholor Do Brasil Based on the Use of Integrated PDCA$/$DMAIC Tools

Francisco de Assis Mour$$o J$$nior$,$ Ed$$lson Marques Magalh$$es$,$ Tirso Lorenzo Reyes Carvajal

Abstract

The general aim of this work was to show a proposal of cost reduction,

for the production process of soft drinks concentrate from Tholor do Brasil Ltda

in Manaus, using the integrated PDCA$/$DMAIC tools, based on the philosophy

of lean manufacturing system and six sigma methodology. About the

methodology, it is a case study that contemplates a documental field research,

carried out with the use of questionnaires to $12$ employees from the soft drinks

concentrate production area of the company, which made possible to achieve the

goals of this work, highlighting from the production employees$$ perspectives,

what improvements can be implemented in the general production process of the

soft drinks concentrate production. The results show that with the

implementation of the integrated PDCA$/$DMAIC tools, in the course of six

months, the loss rate will be reduced by at least $30\%,$ proving the efficiency of

the present proposal, demonstrating the opportunity and modification viability

in this company process, emphasizing the project integration Lean Six Sigma to

the production, through integrated PDCA$/$ DMAIC tool, standardizing methods

to optimize the use of equipment$$s$,$ increasing the labor productivity at all stages

and operational actions of the entire production process, avoiding waste, reducing

cost and increasing the operational efficiency.

Keywords: Concentrate, Tools,

Six Sigma, Lean System, Soft

drinks.

Available online

www$.$bmdynamics.com

ISSN: $2047-7031$

Introduction

The problematic situation detected in the production area of Tholor do Brasil, are related to the

equipment that perform the processes of mixing and homogenizing in the soft drinks concentrate

production. It is a problem relatively easy to be solved, however, it has a great impact in the production.

The solution proposal does not cause major difficulties in its, allowing the company, to obtain

significant gains in the process of search of better continuous improvements, lean production, and

integration with the company necessities, eliminating the failures, reducing time, costs, and operations.

In this context, there was a concern that can be summarized in the following question: how the

philosophy of lean manufacturing system and the six$-$sigma methodology can be applied to improve

the Tholor do Brasil LTDA company soft drinks concentrate production process? The hypothesis of the

work start from the assumption that the processes carried out by mixing and homogenizing that are

used in soft drinks concentrate production of Tholor do Brasil Ltda, add great value to the final product

of the company, and must be continuously analyzed in search of elimination failures and waste, aiming

at continuous improvement and lean production, as well as gains in the production chain, which should

be integrated with the quality tools and collaborate this way with waste reduction, standardization,

and continuous improvement.

Rodrigues $(2014)$ clarifies that the philosophy Lean Manufacturing with its and techniques

have been applied in various sectors of a company, in some cases with changes in the, in others

maintaining the initial terms, but the important is the understanding of the Lean thought, which search

for better results struggling the waste in a broad concept and in all levels, once the organization is lean,

without loss, it is not a more differential, but yes, one more condition of survival in this global and

competitive market.

Considering the high demand for technological innovations by its customers, Tholor do Brasil

Ltda must have a strong model of product design that acts in all sectors involved in manufacturing.

Therefore, constant monitoring of the machines minimizing disruption in the development of products

with speed, safety, and reliability. To produce quality, efficiency and safety is fundamental and in

recent years, the actions of continuous improvement based on lean production process is gaining

prominence in the industrial sphere, given that they subsidize and monitor the decisions that will be

Business Management Dynamics

Vol$\mathrm{.}11,$ No$\mathrm{.}07,$ June $2022,$ pp$\mathrm{.}01-19$

$$Society for Business and Management Dynamics

essential to obtain quality and lower costs. In the context of engineering of industrial processes, a key

reason motivates the accomplishment of works like this: the need to recognize the importance of

continuous improvement and lean manufacturing in a company.

The scarcity of resources coupled with the advent of globalization and fierce competition,

demand of today's enterprises