Productivity Increase in Garlic Classification Process Using Integrated Technology System - Success Case Fazenda São José
Challenge
Avilla Consulting developed a project to improve the production processes of the São José company, aiming to identify opportunities for improvement in garlic processing at the packing house. In this way, with a market currently quite fierce, the need arose to reduce possible losses in the process and increase the use of its resources.
In the initial mapping carried out by Avilla Consulting, some opportunities for financial gain were identified, but this case study aims to mention one in particular: the increase in productivity in the garlic classification process using the integrated technology system.
The methodology used for the analysis of the process was the Chronoanalysis to evaluate the work capacity together with the application of KPI (key performance indicators) to control the amount of machine stops, in addition to the amount of boxes that were turned in the classifiers. to increase productivity through the best use of the machine.
The following steps were carried out:
- Initial mapping of the process;
- Service capacity of the dispensers, responsible for turning the garlic boxes;
- Classifier speed definition;
- Reduction of surplus personnel;
- Implementation of preventive maintenance;
- Standardized job training;
- Validation of standardized work.
Solution
The analysis model implemented by Avilla Consulting, with the objective of increasing the rate of use of the classifiers, was based on statistical metrics and the use of the chronoanalysis method, so that an effective solution could be reached.
At first, in order to verify the capacity of the employees involved, their reasonable expectation was defined, which consists of measuring the time needed to execute one unit per hour, without any interruptions. To this end, the times of the dosers, responsible for turning the boxes in the machine, and the number of classified boxes leaving the machines were checked, in addition to launching any stops that the classifiers presented during the day.
*Some information was withheld due to confidentiality of information
Based on the result above, it was identified that the machines had an unsatisfactory rate of use, as they frequently broke down, resulting in a loss of work rhythm and idleness of the employees who were there, in addition to the loss of productivity due to maintenance.
After this finding, the data were entered into the load-post worksheet, which aims to simulate the need for resources in relation to the demand for boxes per hour.
At the end of the analysis, one can notice a high rate of idleness on the part of the employees who worked as clerks at the exits, as there was not enough demand to justify the amount that was there.
*Some information was withheld due to confidentiality of information
After performing the chronoanalysis, a new layout was defined for both classifiers, considering a reduction of 10 people in total, who were assigned to other areas of the company in which there is added value at work.
*Some information was withheld due to confidentiality of information
*Some information was withheld due to confidentiality of information
With this definition, training was carried out with employees for the adoption of the new processes. In addition to optimizing the process, daily, weekly and monthly preventive maintenance routines were introduced, as well as a general inspection of the machines to replace broken and/or worn parts.
*Some information was withheld due to confidentiality of information
Subsequently, new analyzes showed an increase in the rate of use of the machines, thus generating greater productivity in the entire garlic classification process.
*Some information was withheld due to confidentiality of information
*Some information was withheld due to confidentiality of information
The analyzes showed an increase in the use of both classifiers, in addition to a reduction of 10 people in the process, thus optimizing it.
Results
With the optimization of the process, Fazenda São José achieved a significant financial reduction referring to 10 people in the classifiers, a 37% increase in productivity in the first machine and 25% in the second with the increase in the rate of use of the machinery in the classification process of the garlic.
In addition to the quantitative results, qualitative gains were observed through the qualification of the process managers, obtaining more integration and communication between the sectors and greater engagement on the part of the teams to identify potential improvements.
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