🇧🇷Brazil

Desperdício de Matéria-Prima por Amostragem Manual Inadequada (ABNT NBR 5426)

3 verified sources

Definition

ABNT NBR 5426 specifies precise sample sizes based on batch volume and AQL (Acceptable Quality Level). Manual calculation and selection of samples introduces errors: oversized samples (too much material destroyed), under-sized samples (requiring re-sampling), and duplicate sampling due to lost documentation. Each error costs raw material waste and lab re-run fees.

Key Findings

  • Financial Impact: R$ 25,000–70,000/year (estimated: 5–8 excess sampling cycles/year × R$ 4,000–10,000 material waste + lab re-test fees R$ 1,000–2,000 per cycle)
  • Frequency: Monthly (12 cycles/year); correlates with supplier diversity and batch-size variability
  • Root Cause: Manual AQL/sample size calculation; paper-based sample records; no digital batch-to-sample traceability; inconsistent training on ABNT NBR 5426 sample selection

Why This Matters

The Pitch: Rubber manufacturers in Brasil waste R$ 25,000–70,000 annually on excess sampling waste and repeat sampling. Automated sample-size calculation and digital tracking eliminate over-sampling errors.

Affected Stakeholders

Quality Assurance Technician, Laboratory Manager, Inventory/Warehouse Manager, Procurement (cost tracking)

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Financial Impact

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Current Workarounds

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Methodology & Sources

Data collected via OSINT from regulatory filings, industry audits, and verified case studies.

Evidence Sources:

Related Business Risks

Rejeição de Lote e Multa por Não-Conformidade com ABNT NBR 5426

R$ 50,000–150,000/year (estimated: 10–15 rejected batches × R$ 5,000–10,000 cost per rejection + regulatory fines R$ 10,000–20,000 per violation)

Custos de Retrabalho e Rejeição de Proteínas em Borracha Natural (Certificação de Redução)

R$ 30,000–80,000/year (estimated: 5–8 rework batches × R$ 6,000–12,000 cost per rework + customer refunds/compensation R$ 5,000–10,000)

Atraso na Verificação de Conformidade SBAC (Gargalo Manual na Aceitação de Matéria-Prima)

R$ 40,000–120,000/year (estimated: lost production capacity = 10 days/year ÷ 250 working days × annual revenue; or 20–30 hours/month manual verification × R$ 100–150/hour × 12 months = R$ 24,000–54,000 + idle equipment cost R$ 20,000–60,000)

Desperdício de Energia Elétrica e Impacto em Custos de Produção

5–20% of energy costs annually (estimated R$20,000–R$50,000+ per facility based on typical industrial consumption)

Perda de Capacidade por Falhas de Equipamento Não Detectadas

2–5% annual production capacity loss; estimated R$100,000–R$500,000+ in lost sales per facility (based on typical synthetic fiber/rubber production volumes)

Multas por Comercialização de Luvas Não Certificadas

Estimated penalty range: R$ 5,000–R$ 50,000 per violation (typical administrative fines for selling unregistered medical devices in Brazil). Testing/certification costs: R$ 10,000–R$ 40,000 per product variant. Rework cycles: 30–90 additional days per failed submission = 5–15% delayed revenue.

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