Understanding and Reducing the 709 Equipment Variability to Validate K3/K4 with an Alternate Resin at the Polytechnic University of Puerto Rico

Abstract

This project is focused on the quality assurance hurdles in the injection molding processes of part no. FYA1470, encountered while validating the K3/K4 product using a substitute resin required by the customer. Utilizing the Define – Measure – Analyze – Improve – Control (DMAIC) methodology, the project successfully pinpointed and improved multiple root causes affecting the process. Critical interventions included fixing the resin injection barrel’s temperature controller's malfunction and errors in the measurement program, which led to a reduction in process variability and an enhancement in capability indices. Among the six Critical to Quality (CTQs) dimensions, two did not align with customer specifications, previously defined with the former resin. A CTQ is a characteristic/factor that can affect the product/process quality [1]. On the other hand, as a result of applying the DMAIC methodology, it was determined that CTQ2's performance remained consistent between Operational Qualification (OQ) and Performance Qualification (PQ) phases with the new resin, whereas CTQ3 exhibited marked improvement. To ensure ongoing process stability, control measures were implemented, notably the integration of temperature monitoring into the Preventive Maintenance (PM) and Calibration schedules. A good PM and Calibration program will guarantee a good functioning reducing the risk of unexpected failures [2]. Key Terms - capability indices, Critical to Quality (CTQs) dimensions, DMAIC methodology, process variance.