Reduction of losses in poultry slaughterhouses through of the Analysis and Problem-Solving Methodology (MASP)

Abstract

Poultry slaughterhouses need to improve processes in order to maintain competitiveness, reduce costs, and at the same time, meet market expectations, which are related to compliance with strict quality standards. Throughout the production process of a poultry slaughterhouse, there are many losses, due to the production flow being continuous, and the process being composed of many steps, resulting in several process variables. In this sense, the objective of this work was to apply the Problem Analysis and Solution Method (MASP), supported by the PDCA cycle (Plan, Do, Check, Act) to reduce losses in the whole chicken packaging sector. All stages of the cycle were applied, starting with planning, then implementing the solutions, and finally, checking the results and standardizing the process. From the operational understanding of the process, and the identification of the details and control parameters involved in each of them, it was possible to find the fundamental causes that generate losses in the whole chicken packaging area. The implementation of the action plan and the standardization of actions made it possible to reduce the loss indicator in the whole chicken production process by 37.5%, allowing for an increase in productivity and, consequently, the company's financial gains.