Using Lean Six Sigma Tools for Packaging Machine Rebuild and Automation Process Improvement
Abstract
This document describes the process of
improving an existing packaging machine using
lean six sigma tools and automation technology for
the medical device industry. The ideal
manufacturing site that has volume increase and
high demand, will have no problem in spending
capital for new machine or lines. In the case of a
manufacturing site that has managed to maintain
market share and has a steady volume rate for
years, the machinery and process lines will
eventually reach obsolete technology and a
decrease in output. This is the case of a packaging
machine which was built in the 1960’s and is
currently packaging forty (40) million surgical
blades per year. Using Lean six sigma tools and
automation process improvement it will be possible
to understand better the causes of machine issues
and create plans to improve them. Analysis from
process data shows the major causes of quality
issues are empty packages and major downtime
comes from lot changes. This type of analysis can
be used to include in the machine rebuild scope and
process improvement technology as-well.
Key Terms - Empty Packages, Lot Changes,
Medical Device, Surgical Blades.