A Systematic Approach for Raw Material Scraping Control in a Brazilian Metal-Mechanical Industry

This article shows a systematic approach for raw material scrap control in a Brazilian metalmechanical industry using quality management tools, divided into three stages. First, the scrap reasons were identified using the failure mode and effects analysis. Subsequently, the identified raw material scrap reasons were evaluated and electronically grouped. Lastly, one workflow process and three rework flow actions were developed to minimize raw material scraps. A metal-mechanical industry able to manufacture items for agricultural and automotive parts was explored. A total of 223 raw material scrap reasons were identified, being related to stamping, welding, assembly, and painting processes, grouped into 82 raw material scrap reasons. Before the systematic approach implementation, without grouping raw material scrap reasons, 56% of scraps were categorized as unspecified reasons. After the systematic approach implementation, unspecified reasons decreased to 11.73%, reducing the total cost with unspecified reasons by approximately $55,000.00 in four months.