Identificação de projeção de solda através das ferramentas da qualidade: estudo de caso sobre o excesso de projeção de solda em uma indústria no sudeste brasileiro

Abstract

This study presents a case focused on improving the spot-welding process, aiming to reduce weld projections and consequently minimize production waste in an automotive industry located in southeastern Brazil. The research adopts a qualitative and applied approach, using Quality Tools (QT) particularly the A3 report and the DMAIC (Define, Measure, Analyze, Improve, and Control) method as the main methodologies to identify, analyze, and correct the root causes of the problem. The application of these tools enabled the diagnosis of failures related to the lack of process standardization, equipment wear, and inadequate verification intervals. As a result of the implemented actions, a 30% reduction in weld projection occurrences was achieved, along with the creation of operational standards, employee training, and the establishment of continuous monitoring mechanisms. The results demonstrate that the systematic use of quality tools promotes sustainable improvements in industrial processes, strengthening the quality culture, increasing reliability, and reducing production costs. Therefore, it is concluded that the integration of A3 and DMAIC methodologies is an effective strategy to optimize production processes and enhance operational performance in the automotive sector.