Optimization the process indicator Right First Time under a brewery context Marta Correia Jamal Pinto Gonc¸alves [email protected] Instituto Superior Tecnico,´ Lisboa, Portugal November 2019 Abstract With the intent of optimizing the process indicator Right First Time (RFT) under a brewery context, the current project was developed in Super Bock group’s headquarters in Lec¸a do Balio. The RFT in- dicator reflects the capacity to achieve results of the intended quality in the first attempt throughout the brewing process. Thus, the indicator promotes continuous improvement by facilitating the identification of variations in the process, which have an impact on the quality parameters. The project focuses on the improvement of the following three quality parameters– the original extract, the oxygen dissolved within the filtered beer and the bitterness of the beer during maturation. The cases were selected due to their mostly negative values on the RFT indicator. Work was conducted according to the tools and principles of continuous improvement, more specifically, the DMAIC method from Six Sigma, the 5 Whys analysis, the cause and effect diagram, and the Pareto diagram. This way, it was possible to define the primary problems in each of the parameters and formulate an hypothesis for the existing variations and defects, and, finally, to propose measures to help improve the efficiency of the brewing process. Keywords: Beer Production, Right First Time Indicator, Continuous Improvement, Quality 1. Introduction present work was developed in the production de- partment of Super Bock company. Nowadays, it is thought that a sustainable com- pany is the one that produces less waste, with fewer defects, consuming less resources and pre- 2. Literature Review senting shorter production times and faster pro- 2.1. Beer Production cesses. Consequently, it is suggested, the com- pany is more efficient and competitive in the mar- Brewing is a biotechnological and enzymatic pro- ket [1]. cess [2]. Four raw materials are required for beer The process indicator Right First Time is used to production: barley, hops, water and yeast. The validate the beer quality and the efficiency of the quality of these raw materials has a decisive influ- process. It reflects the capacity to achieve results ence over the quality of beer. of the intended quality in the first attempt through- The most important process within the beer pro- out the brewing process. duction is the fermentation of sugars into alco- Thus, the RFT promotes the continuous improve- hol and carbon dioxide by the yeast. To provide ment of the process by identifying the variation and conditions for the fermentation, it is necessary to problems, enabling changes within it. The goal is produce the wort. To transform wort into beer, always to improve the results of the quality param- the sugars in the wort must be fermented by the eters. With this, the more defects pointed out by yeast. Along with this bioreaction, by-products are the indicator, the greater will be the need for re- formed, which have an effect on the taste, aroma work and therefore more waste will be produced. and other characteristic properties of beer [3]. First of all, it was necessary to identify the most The fermentation of beer is performed in cylindro- prevalent characteristics of the indicator and, con- conical vessels (CCVs). The reactions occurring sequently, in the quality of the product. These were during this process are those occurring in the main identified and prioritized. Besides that, through fermentation and those in maturation. After fer- methodologies and tools of continuous improve- mentation, maturation and lagering, the beer is ment, it was possible to particularize the problems filtered to be stabilized both biologically and col- in order to identify the causes for defects. The loidally. 1 2.2. Quality and Continuous Improvement cause and effect diagram. Quality is described as the added value delivered 3.1. Case Study I- Original extract at filtered beer to the client, and is generally regarded as excel- The first case study is based on the elimina- lence. Due to the competitiveness of the market, tion/reduction of out-of-specification original ex- companies work to achieve the quality expected tract results in the first attempt at filtered beer. by the consumer. To achieve the expected quality, The quantity of dissolved sugars present in the the process is constantly improved [4]. wort before fermentation is known as original ex- Continuous improvement is defined as an inte- tract. It is expressed in Plato Units (◦P)– quantity grated tool to affect the process or service with of sugars (g) per 100g of wort. the aim of improving the quality and productivity. It is also described as a culture, where everyone 3.1.1. Define Phase contributes to produce improvements without the The first step was to define and specify the prob- need of major investments [5]. lem. To accomplish this, the influence of products on the RFT for this characteristic was investigated; 2.3. DMAIC Methodology the products of interest were selected; the influ- The DMAIC method (Define–Measure–Analyse– ence of the filtration line and the stage of the fil- Improvement–Control) is an approach that seeks tration cycle on the out-of-specification results was to reduce variability along the process with the pur- determined. The main problem was identified as pose of minimizing the waste and achieving the ex- filtrations of product X and Y in the filtration line 2 pected quality. and prevalently at cycle ends. For that, first of all, it is necessary to define the 3.1.2. Characterisation of the current situation problem (define), than to quantify the current sta- Once the problem has been defined, the mode of tus of the project (measure), analyse the data and operation of the filtration line in question has been formulate hypotheses for the causes of the problem identified taking into account the different stages (analyse), implement solutions to minimize or elim- of the filtration cycle and also the understanding inate the causes effects (improvement), and check of the online dillution and carbonation process. In if the desired results were achieved through the addition, the measuring instruments in the line and changes made (control) [6]. their mode of operation were identified. 2.4. Right First Time Indicator 3.1.3. Measure Phase RFT is broadly used in several industries to vali- Data collection was performed and the current date the quality and efficiency of the process [7]. deviations presented by the online original wort The indicator reflects the capacity to achieve the measuring instruments (DSRn 427S and mPDS desired quality results in the first attempt. The max- 2000V3 Evaluation Unit) were quantified in rela- imum process efficiency is reached when the indi- tion to the measuring of the measuring apparatus cator is at 100 %. According to this, it is possible present in the laboratory (Alcolyzer Beer). For this to identify the problems and variations during the purpose, each sample is defined as the beer taken process easily. It has the benefit of reducing costs online each time during the filtration of product X due to reduced product reprocessing. and Y. Sampling, the process of collecting samples 3. Materials and Methods at the terminal of the filtration line using a Scan- The present study followed an approach focused dibrew tap for that purpose. Table shows the num- on identifying the quality parameters which most ber of samples that have been collected for both negatively influence the process indicator. There- products (X and Y) and their concentration range. fore, first, they were identified and then selected as Table 1: Set of samples collected at filter line 2 for product X case studies. and Y. Since, in the company, the RFT is determined by Product Concentration Number of samples the average of RFT in the fabrication (of the wort) X 10.97– 11:31◦P 26 and RFT in the filtration, the cases were selected Y 12.36–16:95◦P 11 separately, i.e., considering the characteristics that affected fabrication and filtration. At the company, the indicator regarding with fabrication is calcu- 3.1.4. Analyse Phase lated by the results in maturation. The selection Considering the characterization of the current sit- was made by the Pareto diagram. uation carried out and by the analyse made re- Then each case study was handled independently garding to the measure phase it was possible to by the DMAIC method. Also, potential causes were pointed out some of the main causes. The identi- pointed out using the 5 Why’s analysis and the fied causes have been brought together in a cause 2 and effect diagram. At this point, since common Table 2: Set of samples collected. causes were found for other products, the prob- Type of tank Number of samples lem was extended to products other X and Y. The 3000 hL 3 causes were discussed for further analysis. 3000E hL 4 1000E hL 17 3.1.5. Improving phase Finally, solutions were prioritized taking into ac- 3.2.3. Analyse Phase count the causes identified. Not all the proposed The data collected was analysed and root-causes solutions were carried out during the internship pe- were identified by the use of 5 Why’s tool. riod but are thought to contribute to improvement of the current situation. 3.2.4. Improving Phase The possible causes were identified and prioritized 3.2. Case Study II- dissolved oxygen at filtered beer for future improvement tests. Then three different tests were performed to reduce or eliminate three 3.2.1. Define Phase of the causes pointed out by 5 Why’s too. First, the influence of filtration lines on out-of- 3.2.5.