Applying quality tools to reduce Other Waste in a disposable diaper factory

Authors
DOI:
https://doi.org/10.47456/bjpe.v11i2.47761
Keywords:
Waste, Quality Tools, Other Waste, Solid waste reduction
Abstract

This study aimed to identify and mitigate waste in the manufacturing of disposable diapers in a factory in Bahia, using quality tools. The company, which is the object of study, deals with complex industrial processes, which include the combination of raw materials such as cellulose, superabsorbent polymers and non-woven fabrics for the production of non-durable consumer goods, with an emphasis on personal hygiene. The production system is automated, on a large scale, but requires strict control to prevent waste. Using tools such as brainstorming, Pareto chart, Ishikawa diagram and the 5 Whys, this study focused on identifying and mitigating the causes of waste of primary materials, called Other Waste. The application of the tools had the participation of the operations team and validation took place in daily meetings, which culminated in training actions, operational adjustments and predictive maintenance. The results demonstrated an average reduction of 51.6% of waste from machine 1 and 65.9% from machine 2, evidencing the effectiveness of the implemented actions. In addition to improving economic efficiency, this research highlighted the importance of integration between operational and maintenance teams, promoting a cultural change that strengthens trust in automated systems.

Author Biographies
  1. Maylane Neres Costa Santos, Federal University of Recôncavo da Bahia

    Graduating in Production Engineering from the Federal University of Recôncavo da Bahia (UFRB), with experience in process optimization, people management and continuous improvement. She currently works in Clinical Engineering, applying engineering knowledge to improve operational and strategic processes. She has also worked in the environmental area, developing analyses and contributing to the mitigation of environmental impacts. Seeking to broaden her experience in the industrial sector, she has worked directly in the process, acquiring technical skills and participating in projects aimed at reducing waste and improving production efficiency. She also has experience in people management and administrative processes, where she has worked on structuring and optimizing organizational flows, implementing team development strategies and improving internal communication. Her academic background includes voluntary participation in a Scientific Initiation project in the field of Operations Research, as well as working as a researcher in Industry 4.0, deepening her knowledge of innovation and digital transformation in the production sector. With an approach focused on efficiency and innovation, she is always looking for new challenges and opportunities to optimize processes and add value to organizations. https://lattes.cnpq.br/6096875448941265

  2. Natália Macêdo e Silva, Federal University of Recôncavo da Bahia

    She works as a quality trainee at Pirelli, where she applies my knowledge of process control and continuous improvement, correlating the technical basis developed during her degree with a holistic view of energy efficiency, sustainability and industrial processes.

    In previous experiences, he developed essential skills such as assertive communication, critical thinking and teamwork. He also acquired practical knowledge of OEE (Overall Equipment Efficiency) and chronoanalysis, contributing to the optimization of production processes.

    He believes that the success of organizations is directly linked to people's potential and ability to innovate. That's why he is always looking for solutions that combine technical efficiency, collaboration and continuous improvement to generate sustainable, high-impact results.

  3. André de Mendonça Santos, Federal University of Recôncavo da Bahia

    Assistant Professor at the Federal University of Recôncavo da Bahia in the Production Engineering and Interdisciplinary Bachelor's Degree in Engineering and Sustainability, in the area of Projects/Product Engineering. Production Engineer graduated from the State University of Santa Cruz (UESC). Master's degree in Materials Science, Innovation and Modeling from UESC. PhD in Industrial Engineering from the Federal University of Bahia (UFBA). I have experience in Production Engineering, working mainly on the following subjects: process simulation and optimization, Entrepreneurship, Service Management and Industry 4.0. I also have experience in the area of Chemical Engineering, having worked on research in the following areas: polymer composites reinforced with natural fibers and ways of preventing corrosion in metallic materials.

  4. Eron Passos Andrade, Federal University of Recôncavo da Bahia

    Adjunct Professor at the Federal University of Recôncavo da Bahia - UFRB, with a PhD and Master's degree in the Industrial Engineering Postgraduate Program at the Federal University of Bahia - UFBA. Graduated in Production and Systems Engineering from the State University of Santa Cruz - UESC. Permanent Professor in the Postgraduate Program in Intellectual Property and Technology Transfer for Innovation - PROFNIT/UFRB. He has experience in the area of Production Engineering, with an emphasis on Organizational Engineering, working on the following topics: technological innovation, Triple Helix, intellectual property, strategy and organizations and business process management. He mainly researches the contributions of Brazilian public universities to the process of technological innovation.

  5. Djoille Denner Damm, Federal University of Recôncavo da Bahia

    He is an adjunct professor in the Production Engineering course at the Center for Science and Technology in Energy and Sustainability (CETENS) of the Federal University of Recôncavo da Bahia (UFRB). He has a PhD in Materials Science and Engineering from UNIFESP. She holds a master's degree in Materials Science, Innovation and Modeling from the State University of Santa Cruz (2016) and a bachelor's degree in Production and Systems Engineering from the State University of Santa Cruz (2012). He has professional experience in the pulp bleaching chemical industry. In the area of Production Engineering, she has worked with the Planning, Design and Control of Production Systems and with the following topics: development and improvement of production processes, lean manufacturing, process management, situational leadership and management of resources, costs and people. In the field of scientific research, he works on the following topics: reuse of scrap aluminum, polymer fiber and resin composites, deposition of diamond films by vapor phase carbon deposition (CVD), carbide deposition through reactive thermodiffusion (TRD), carbide deposition through Laser Cladding (LC), reactive thermodiffusion (TRD), characterization and analysis of interfaces, surface engineering, surface tribology. http://lattes.cnpq.br/5898510105679183

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Published
2025-05-15
Issue
Vol. 11 No. 2 (2025): Regular Issue (April - June)
Section
OPERATIONS & PRODUCTION PROCESS
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Copyright (c) 2025 Maylane Neres Costa Santos, Natália Macêdo e Silva, André de Mendonça Santos, Eron Passos Andrade, Djoille Denner Damm (Autor)

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How to Cite

Santos, M. N. C., Silva, N. M. e, Santos, A. de M., Andrade, E. P., & Damm, D. D. (2025). Applying quality tools to reduce Other Waste in a disposable diaper factory. Brazilian Journal of Production Engineering, 11(2), 160-178. https://doi.org/10.47456/bjpe.v11i2.47761