Manufacturing Engineering
Permanent URI for this collectionhttps://hdl.handle.net/20.500.12475/53
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Item Lean Manufacturing Implementation to Improve Process Capability and Performance(Polytechnic University of Puerto Rico, 2022) Orama Negrón, Yanairy; Morales, José A.Industries has been continuously evolving with the change in tendencies and market growth of products. To be capable of maintaining the organization competitiveness, in front of an aggressive market, production capability and cost reduction is desired. Company X is dedicated to the design and manufacturing of customizable packaging and promotional merchandise. It was identified some factors affecting the deliverables of the production floor, such as inefficient layout design. Lean manufacturing is a tool widely used by many industries to reduce waste in processes. Applying this tool into production processes, allows to reduce wastes in process and to reduce production costs and defect ratio. DMAIC (Define, Measure, Analysis, Improve and Control)was the methodology used to improve the outputs of the production floor of Company X. At the end of the project an improvement of 15% on the productivity was observed; in addition, the defect rate was reduced by 33%.Key Terms: 5’S,DMAIC,Lean Manufacturing, Waste Reduction.Item Mejora en el Proceso de Limpieza en los Equipos de Manufactura(Polytechnic University of Puerto Rico, 2022) Rivera, Ivette; Morales, José A.Durante estudios de tiempo en los procesos en una farmacéutica en Puerto Rico se identificó un tiempo prolongado en la ejecución de limpieza de la Compresora que es compartida con varios productos .Por esta razón la planta se propuso como objetivo reducir el tiempo de la limpieza para poder manufacturar más lotes.Para mejorar la limpiezase utilizó la metodología de validación de limpieza y “Lean Six Sigma”. La limpieza fue mejorada y validada demostrandola remoción de residuos. La reducción de tiempo en la limpieza fue de 50% y un 54% en el costo ya que se disminuyó el consumo de utilidades y de tiempo. Esta reducción incrementó la cantidad de lotes manufacturados. Por tanto, las mejoras a la limpieza fueron satisfactorias quedando pendiente los “Hold Times”. Como parte de las regulaciones para los procesos de limpieza en la industria farmacéutica se espera que se valide los “HoldTimes”. Términos claves⎯ DMAIC,“Hold Times”, “Lean Six Sigma”, Optimización de limpieza, Reducción de tiempo, Validación de limpieza.Item Reducción de Desperdicio en el Proceso de una Pizzería(Polytechnic University of Puerto Rico, 2019) Santiago Rosado, Yadira; Morales, José A.Este proyecto se realizó en una pequeña pizzería en el pueblo de Ponce. Como parte del proyecto se observó y evaluó el proceso operacional de este comercio. Se identificaron desperdicios definidos en el sistema de lean manufacturing. Y se trabajó para reducir estos desperdicios. Se utilizó la herramienta de diagrama de espaguetti. El diagrama de espaguetti fue clave en el proceso de identificación de desperdicio y evaluación de alternativas. Se evaluaron las distintas alternativas y se hicieron pruebas piloto para asegurar el resultado de cada alternativa a ser recomendada. En conclusión, se le recomendaron dos alternativas al dueño de la pizzería. Una alternativa que utiliza los recursos ya poseídos y una alternativa que requiere de una inversión. Además se le recomendó como proyecto futuro una aplicación para automatizar las ordenes. Palabras Claves ⎯ Círculo de Deming, Diagrama de Espaguetti, Kaizen, Lean Manufacturing.Item Standardizing the Manufacturing Operation of a Multipurpose Cleaner in 32-Ounce Bottles in Order to Control the Process(Polytechnic University of Puerto Rico, 2019) Ortega Rodríguez, Nicole M.; Morales, José A.With the fast paste life we are currently living, manufacturers are always looking for innovative ways to simplify products, including cleaning and household products. With an allpurpose cleaner, there is no need to buy and store different bottles thus simplifying household chores. These products are designed to act as disinfectant, detergent, de-greaser, solvent or a combination to be used on different surfaces. In Puerto Rico, you can find many companies that are currently manufacturing these types of multi-purpose cleaners that are typically found in any household. This project is based on a multipurpose cleaner manufactured in Puerto Rico which has been in the market since 1997. It is a multipurpose cleaner capable of cleaning any surface without damage, strong against dirt and grease, but not harmful to the skin. It is a noncorrosive, non-abrasive and eco-friendly product used in many households today. Key Terms ⎯ Manufacturing Process Control, Multipurpose Cleaner, Reducing Process Variation, Standardizing Manufacturing Operation.Item Reliability of Operators performing the Visual Inspection of Parenteral Drug Products(Polytechnic University of Puerto Rico, 2010) Adams Monell, Glorynette; Morales, José A.The visual inspection of parenteral product filled vials is performed to assure that any damaged or defective unit is detected and removed prior to packaging. This investigation evaluated the visual inspection process of parenteral products with manual handling to enhance actual process and reduce regulatory exposure. It challenged the probabilistic inspection results due to variability within operators and inspection time. A total of three (3) different standard sets of 100 vials each were evaluated by three (3) inspectors of high, medium and low experience level. The study concluded with a 95% confidence level that there is no significant difference between the results obtained at forty (40) and fifty (50) seconds inspection time neither between the interaction of inspectors and inspection time but that there is significant difference between operators. Consequently, initial and continuous training are essential elements for the quality assurance of the visual inspection process. Key Terms – analysis of variance, operators reliability, parenteral products, visual inspectionItem Reducción en el Tiempo de Procesar Órdenes de Servicios Especiales en Telecomunicaciones(Polytechnic University of Puerto Rico, 2013) Ortíz Pérez, Santos E.; Morales, José A.La competencia que ofrece las nuevas compañías en el mercado de las telecomunicaciones ha impulsado a las compañías tradicionales a buscar alternativas que ayuden a mejorar la calidad de sus servicios. Estudios en el mercado reflejan inquietudes entre los clientes de compañías tradicionales en torno al tiempo que demora la instalación de órdenes de servicios especiales. Casos del pasado, analizados, tomaron en promedio 120 días en ser resueltos, lo que estaba muy lejos de las expectativas del cliente. Mediante este proyecto se pretende reducir el tiempo en espera de un cliente desde que genera una orden de servicio hasta que la misma es completada. Mediante los cambios propuestos se pretende reducir este tiempo de 120 a 30 días. Términos Claves - Metodología DMAIC, Órdenes de Servicio (DON), Órdenes de Trabajo de Planta (OTP), Voz del Consumidor (VOC).Item Optimization of the Qualification Process to Improve Products and Services in a Telecommunication Industry(Polytechnic University of Puerto Rico, 2013) Santiago Dasta, Mellanie; Morales, José A.This design was based on standardizing the qualification process, reduce the time to increase production and improve the process of updating the information on the server. The Kaizen event helped to solve different problems and conditions found in the qualification process to provide customers with high quality products and services. Also create a working group responsible for providing solutions and ideas. The value stream map and the elimination waste were performed to identify the value added and non-value added in each step of the process. The results with the plan implementation were favorable allowing savings to the company, reducing the time by 70% and increasing production by 41% in six months with the help of a staff committed to continuous improvement to compliance with the proposed objectives. Key Terms – Kaizen for Telecommunication, Lean Manufacturing, Server Process Improvement, Telecommunication Systems.Item Validation of a New Procedure for a Pacemaker Component(Polytechnic University of Puerto Rico, 2012) Farahmand, Marguerite; Morales, José A.Abstract - Company X manufactures pacemakers in Puerto Rico. Over the past years, Company X has been having a significant amount of complaints due to the septum component contained in its pacemakers. Doctors have claimed that during the surgical process of implanting the pacemaker device in the patient, the septum component detaches itself from the device, rendering the device unusable. This validation project presents both the Product Performance Qualification (PPQ) and Installation Operational Qualification (IOQ) of the new septum that will replace the current one that is presenting complaints and its corresponding Controlled Environmental Humidity Chamber. Key Terms - Pacemaker, Septum, Controlled Enviromental Humidity Chamber and Medical Adhesive (Med A).Item Improving Efficiency of the Filling Line in a Dairy Industry(Polytechnic University of Puerto Rico, 2013) Moró Pérez, Eduardo; Morales, José A.In the dairy manufacturing company the efficiency of the juice filler line is around 53%. We are trying to improve it to around 70% or more. In this project we used the DMAIC methodology for process improvement. Through the first week of data observation a clear tendency is seen throughout the process. Those bottlenecks of the process are the full refrigerator, slow bottles flow and caser mechanism. A cause and effect and pareto charts were developed after a brainstorming with the operators and the mechanics. After those analyses it was found the root causes of the problems. A visual aid by the machines was proposed to increase communication between operator and mechanics. After the implementation the operators, mechanics and internal suppliers should receive continuous training using that new mechanism to report failures. It is also important to keep the process within the specifications to avoid the possibility of muda (waste). Key Terms ⎯ Dairy, DMAIC, Filler, Production.Item Improving Steroid Out Of Specification (OOS) Trending on Pacemaker Lead(Polytechnic University of Puerto Rico, 2013) Martínez Crespo, Víctor; Morales, José A.The purpose of this project is to identify a roots cause and potential factors that influencing Steroid Out Of Specification Results (OOS) on pacemaker lead model XYZ. Project involves Define, Measure, Analyze, Improve and Control (DMAIC) problem solving methodology. The objective of the study is to decrease Failure Test Rate from 15% to 10%. The contribution will allow the optimization of the steroid application process, by control the potential factors that contribute the (OOS) results. This project might be used as benchmark to implement similar problem solving techniques around the manufacturing plant or as a model for other educational needs. Key Terms ⎯ Combination Products, Out of Specification Trending, Pacemaker Lead, Steroid.