Scrap Reduction Evaluation of Filling Equipment and Short-Term Improvement Implementation
Abstract
This paper seeks to document an
approach to reduce scrap losses using the Lean Six
Sigma tools for process improvement in a lean
manufacturing environment. The Lean Six Sigma
methodology views lean manufacturing, which
addresses waste issues, and Six Sigma, with its
focus on design, as complementary disciplines
aimed at promoting "business and operational
excellence”. DMAIC (Define, Measure, Analyzed,
Improved, and Control) is used for projects aimed
at improving an existing business process.
Assessments of the manufacturing processes and
interviews with key personnel to determine
potential opportunities were performed by means of
Voice of the Costumer. The project starts with the
definition and measure phases, followed by the
analysis phase and ends with improve and control
phases. Supporting data are presented using Pareto
charts to prioritize waste in order to be more
focused for improvement. DMAIC methodology was
employed to identify the areas in which the product
is discarded (waste). Evaluation revealed that the
product that remains in the silastic hose and not
transferred in the carboy is the major contributor
of the product loss at the filling stage. Scrap
reduction into filling equipment was successfully
employed to improve manufacturing productivity.
Twenty five percent (25%) of cost improvement
were the immediate benefits attained from
implemented process improvements.
Key Terms - DMAIC methodology, Lean Six
Sigma, Voice of the Costumer (VOC), Waste.