Output Improvement for a Blister Packaging Line using Lean/Six Sigma

Abstract

Abstract - With the pass of the years industries are looking to reduce costs associated to packaging process. In the packaging line analyzed for this project product is packed in blister cells at primary packaging by two blistering machines. Since January 2010, Product A packaging process average output is 44 blisters per minute. The objective of this project is to improve the packaging output and consistently achieve a takt rate of 46 blisters per minute with one blistering machine. Lean Six Sigma Methodology and tools were used to drive the project, analyze data, document results and establish the controls to sustain the improvements. Some of the tools used were: SIPOC, Voice of the Customer, Cause & Effect Diagrams, Control Charts and Analysis of Variance. As project results, objectives were met by increasing packaging takt rate from 44 to 46 blisters per minute and reducing process variability by 45% with one blistering machine. Key Words – Blister Packaging, Primary Packaging, Secondary Packaging, Six Sigma.