Pesquisa-ação sobre os fatores de sucesso para implantação e continuidade do uso de cartas de controle estatístico de processo em uma planta química no Brasil
Santana Júnior, Manoel Bispo de
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Statistical process control charts (SPC charts) were created in the 20th century in the United States and since then, they have been used for various purposes in different industries and services. SPC chart utilization was widespread in Japan in the postwar period and its effective use in Brazil occurred from the 90´s. Although several examples of use, there are still some industries where deployment of SPC and its sustained use in shopfloor were not successful. In the chemical industry, its use in the shopfloor is controversial and there is no many studies focused on this industry to explain the factors that can impact the successful implementation of statistical control charts by operational teams. This dissertation aims to investigate, through an action research, which are the critical factors for a successful implementation and sustained use of SPC charts in a chemical. It was performed a literature review to gather studies about success factors to implement SPC chart in industries. Using action research, those critical success factors were tested in practice with operators in the chemical plant of a multinational enterprise located in Brazil. This chemical plant has experimented to implement SPC chart in the past with no success. As a result of the action research, we succeed to implement SPC chart in the industrial unit and reduce variability with savings of US$ 150,000.00 per year energy. SPC chart use was well received by operators and leadership, showing that some success factors are really critical for a correct SPC implementation in a brazilian chemical plant. The results were used to develop a roadmap for SPC, with details about how and when to work each success factor. Afterwards, Roadmap was used in another eight different industrial units of the chemical company, all with success.
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