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Advisor(s)
Abstract(s)
A cerveja é uma bebida com valor económico que pode ser quantificado pela quantidade
do seu extrato. O extrato corresponde à quantidade de açúcares extraídos dos cereais
(matérias-primas) durante a etapa de fabricação de mosto, sendo estes necessários à fermenta
ção alcoólica. A contabilização do extrato é a forma mais objetiva de se quantificar
a concentração do mosto ou da cerveja a processar. A quebra de extrato corresponde ao
extrato perdido num processo ou sistema. A redução da quebra de extrato é um objetivo
de elevada prioridade para a Sociedade Central de Cervejas (SCC), logo após a abolição
dos acidentes de trabalho, o objetivo de primeira prioridade, pois cada unidade percentual
da quebra de extrato global traduz-se numa perda de milhares de euros para a empresa.
A gestão da área de Supply Chain desta empresa é realizada, desde 2005, pelo Total Productive
Management (TPM). Este programa de excelência permite definir os objetivos a
cumprir anualmente em cada Pilar de Gestão Autónoma na SCC. Um dos objetivos de
maior prioridade é a redução da quebra de extrato global evitável da empresa, tornandose
este o foco do presente trabalho através da identi cação e quantificação de Pontos de
Quebra de Extrato no processo de fabricação e a procura de Ações de Melhoria (AM)
sustentáveis. O TPM contribui com ferramentas que conferem suporte metodológico ao
trabalho, tais como o Value Stream Mapping (VSM) e o Unified Problem Solving (UPS).
Na área de estudo (Fermentação e Maturação de cerveja) foram identificadas 17 Oportunidades
de Melhoria (OM), das quais 4 (OM nº1, nº6, nº7 e nº15) foram analisadas e
quantificadas ( ------ de impacto na Quebra de Extrato global do processo, respetivamente)
e convertidas em Ações de Melhoria para futura implementação na empresa (AMI nº1.2.1,
nº6.1/6.3, nº15.1.1/15.1.2). Em termos de implementação, a AMI nº1.2.1 foi implementada
em março de 2019 a todas as receitas de cerveja e as AMI nºI.I e nº15.1.1/15.1.2 têm
previsão de implementação em 2020.
Globalmente, caso sejam implementadas todas as AMI sugeridas neste trabalho, conseguindose
uma eliminação completa da quebra de extrato em cada ponto, obter-se-ia uma redução
de aproximadamente 20% da quebra de extrato global evitável do processo verificada em
2018.
Beer is an economic valuable beverage that can be quantified by the amount of its extract. The extract corresponds to the amount of sugars extracted from the cereals (raw materials) during the wort production, which are needed for alcoholic fermentation. Accounting for the extract is the most objective method to measure the concentration of wort or beer to be processed. Extract loss is the true losses in a process or system. Reducing extract loss is a high-priority objective for Sociedade Central de Cervejas (SCC), right after the elimination of accidents at work, which is the first priority objective, as each percentage unit of global extract loss results in the loss of many thousands of euros. The management of Supply Chain in this company has been carried out, since 2005, by Total Productive Management (TPM). This program of excellence allows you to define the objectives to be achieved per year in each Autonomous Management Pillar at SCC. One of the top priority objectives is to reduce the avoidable global extract loss of the company. This is the aim of this research that will identify and quantify Extract Loss Points in the production process and will look for sustainable Improvement Actions (AM). TPM contributes with tools that give methodological support to the study, such as Value Stream Mapping (VSM) and Unified Problem Solving (UPS). In the study area (Fermentation and Beer Maturation) 17 Improvement Opportunities (OM) were identified, of which 4 (OM nº1, nº6, nº7 and nº15) were analyzed and quantified ( ----- of impact on the overall Extract Loss of the process, respectively) and converted into Improvement Actions for future implementation in the company (AMI nº1.2.1, nº6.1/6.3 and nº15.1.1/15.1.2). As for implementation, AMI nº1.2.1 was carried out in March 2019 in all beer revenues and AMI nºI.I and nº15.1.1/15.1.2 is expected to be implemented by 2020. Globally, if all of the AMI suggested in this work are implemented, obtaining a full elimination of each extract loss point, leads to a reduction of approximately 20% in the process avoidable overall extract loss observed in 2018.
Beer is an economic valuable beverage that can be quantified by the amount of its extract. The extract corresponds to the amount of sugars extracted from the cereals (raw materials) during the wort production, which are needed for alcoholic fermentation. Accounting for the extract is the most objective method to measure the concentration of wort or beer to be processed. Extract loss is the true losses in a process or system. Reducing extract loss is a high-priority objective for Sociedade Central de Cervejas (SCC), right after the elimination of accidents at work, which is the first priority objective, as each percentage unit of global extract loss results in the loss of many thousands of euros. The management of Supply Chain in this company has been carried out, since 2005, by Total Productive Management (TPM). This program of excellence allows you to define the objectives to be achieved per year in each Autonomous Management Pillar at SCC. One of the top priority objectives is to reduce the avoidable global extract loss of the company. This is the aim of this research that will identify and quantify Extract Loss Points in the production process and will look for sustainable Improvement Actions (AM). TPM contributes with tools that give methodological support to the study, such as Value Stream Mapping (VSM) and Unified Problem Solving (UPS). In the study area (Fermentation and Beer Maturation) 17 Improvement Opportunities (OM) were identified, of which 4 (OM nº1, nº6, nº7 and nº15) were analyzed and quantified ( ----- of impact on the overall Extract Loss of the process, respectively) and converted into Improvement Actions for future implementation in the company (AMI nº1.2.1, nº6.1/6.3 and nº15.1.1/15.1.2). As for implementation, AMI nº1.2.1 was carried out in March 2019 in all beer revenues and AMI nºI.I and nº15.1.1/15.1.2 is expected to be implemented by 2020. Globally, if all of the AMI suggested in this work are implemented, obtaining a full elimination of each extract loss point, leads to a reduction of approximately 20% in the process avoidable overall extract loss observed in 2018.
Description
Relatório de estágio para obtenção do grau de mestre em Engenharia Química e Biológica
Keywords
Cerveja Beer Quebra de extrato Extract loss Value stream mapping Uni ed problem solving Sociedade Central de Cervejas Análise de 5 porquês Root cause failure analysis
Citation
SANTOS, Francisco João Noronha dos - Quebra de extrato na fabricação de cerveja. Lisboa: Instituto Superior de Engenharia de Lisboa, 2019. Dissertação de mestrado.
Publisher
Instituto Superior de Engenharia de Lisboa