Uso de análise de causa raiz para bloqueio de perdas de produção em plantas industriais

Abstract

The article analyzes a strategic approach to maintenance that extends the focus of maintenance. The maintenance process becomes relative to the whole production process, incorporating efforts to avoid production losses. Through this strategy hoping to obtain and maintain maximum productivity, focusing on total losses of the process. An effective management action passes through the development and implementation of a system that can maximize the benefit / cost ratio of maintenance activity by identifying and quantifying the losses. The company that was studied uses Global Efficiency Index - IEG as an indicator of performance of equipment, production line or of an operating system. The results of the IEG are impacted by availability, capacity and quality. IEG is the ratio between the specified production volume obtained and maximum possible production in a given period of time. As a guideline of the company, all losses of industrial production (due to equipment failures and process failures) require a mandatory root cause analysis (RCA) of the failure, within 30 days of the official consolidation of the event. The RCA should identify all physical, human and latent causes of this failure in order to prevent reoccurrences. These analyses must be performed by a multidisciplinary group involving representatives of the maintenance, process and production areas of the company with a focus on reliability. The RCAs generate actions in order to block future production losses due to the same or similar reason as that of the event analyzed. For the equipment, the actions are performed primarily to increase the level of predictability of the events. The proposed modifications and improvements should eliminate the causes or minimize the effects of the failures, extend the life cycle, ensure the effectiveness and guarantee some sort of return for equipment management.