Continuous improvement in cotton processing: a case study

Authors
DOI:
https://doi.org/10.47456/bjpe.v11i4.49494
Keywords:
Agribusiness, Quality Management, Statistical Quality Control, Cotton
Abstract

This study aims to analyze the production process of a cotton processing company, applying quality tools and statistical methods as a basis for continuous process improvement. The research is characterized as applied and experimental, with a quantitative approach, conducted in a real industrial environment. Critical process variables were evaluated, such as temperature, cotton humidity at different stages, feed rate, and equipment rotations, comparing scenarios with incorrect and correct parameters. The data were subjected to statistical analysis and instrumental verification in the laboratory, making it possible to identify the main causes of variation in operational performance. The results showed high variability in bale weight, with 77.6% non-conformity in relation to the specified limits, with 41% below and 36.6% above the standard weight. The main causes identified are related to operational failures, environmental variations, and lack of standardization between shifts. The application of quality tools allowed the identification and prioritization of the causes with the greatest impact, directing corrective actions aimed at standardizing humidification and pressing, improving communication between operators, and preventive maintenance of equipment. The study highlights the scientific relevance of integrating quality management and industrial statistics as support instruments for decision-making and continuous process improvement in agribusiness.

Author Biographies
  1. Rian Moura Café Amorim, Federal University of Campina Grande

    Production Engineer | Agro-industrial Coordinator - UBA | SLC Agrícola S/A

  2. Keren Karolyne Nóbrega Silva, Universidade Federal da Paraíba (UFPB)

    I am driven by engagement. I believe that genuine dedication is what transforms projects into real results, so I dive intensely into every challenge I take on. I see work as a continuous learning opportunity, while I seek to keep alive the critical and curious perspective of someone who also enjoys writing and reflecting on what they experience.
    My background in Production and Systems Engineering has shown me that engineering goes far beyond optimizing processes. It's about connecting people, data, and strategies to transform organizations. During my undergraduate studies, I worked with strategic project management, operations research, and marketing. In my master's program, I am deepening my trajectory by studying sustainability engineering as a competitive advantage, with an emphasis on the theory of dynamic capabilities and the circular economy.

    I strive to move naturally between the academic world and the corporate world, where I work with indicator management, project monitoring, strategic definition, data-driven decision making, standardization, and control. I use Power BI to translate complex information into clear and visually appealing presentations, facilitating communication and decision-making.
    I have a special interest in topics such as organizational engineering, quality, innovation, and knowledge management, and I maintain an active link with volunteer initiatives focused on teaching and multidisciplinary collaborative work.
    I value environments where learning, purpose, and results go hand in hand, as this is what I seek to build daily in my professional journey.

  3. Yuri Laio Teixeira Veras Silva, Federal University of Campina Grande

    Adjunct Professor at the Production Engineering Unit of the Federal University of Campina Grande. He has experience in the major areas of Production Engineering, especially in operations research and simulation, production management, investment analysis, logistics and supply chain, with a focus on the implementation of decision-making support tools, based mainly on mixed integer programming approaches, non-linear, stochastic models, meta-heuristics, artificial intelligence and computational simulation approaches.

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Cover Image
Image showing a close-up of a cotton field with several white cotton bolls ready for harvest under a clear blue sky. The title on the image reads “Continuous Improvement in Cotton Processing: A Case Study,” with the authors’ names and the logo of the Brazilian Journal of Production Engineering.
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Published
2025-11-12
Issue
Vol. 11 No. 4 (2025): Regular Issue (October - December) *Continuous Publication of Articles
Section
QUALITY ENGINEERING
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Copyright (c) 2025 Silva, K. K. N., Amorim, R. M. C., & Silva, Y. L. T. V.

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How to Cite

Amorim, R. M. C., Silva, K. K. N., & Silva, Y. L. T. V. (2025). Continuous improvement in cotton processing: a case study. Brazilian Journal of Production Engineering, 11(4), 180-193. https://doi.org/10.47456/bjpe.v11i4.49494