Quality Sampling Plan Re-Design for Secondary Packaging Operation for the Graduate Program at Polytechnic University of Puerto Rico

Abstract

A significant decrease in the lot size has been observed year to year and volumes expected to increase by mid2021. Therefore, there was the need to evaluate alternatives to enhance the current Quality Assurance (QA) Inspection Regime to provide flexibility to the Secondary Packaging Operations. As part of the evaluation, sampling plan alternatives for the Cosmetic Defect inspection were evaluated, which can accommodate lot size variations, provide flexibility to meet service needs and avoid or minimize recruitment of further personnel because of expected volume increase. To archive this goal, it was required a reduction of 30% of the current cycle time for the QA audit process. Using lean manufacturing principles and DMAIC methodology to develop this project, a reduction of a 62% in cycle time during the QA audit process was obtained. The implementation of this project exceeded the objectives of the project, sustaining the existing Quality Standards. Key Terms ⎯ Sampling Plan, DMAIC, Quality Assurance audit, and Statistics.