Manufacturing Engineering
Permanent URI for this collectionhttps://hdl.handle.net/20.500.12475/53
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Item Lean and Safe Manufacturing for an Antidepressant Tablets Coating Process(Polytechnic University of Puerto Rico, 2009) Torres Santiago, Meraris; Zárate, PatriciaAbstract - The Lean and Safe Manufacturing Process (6S event) was selected for implementation in an antidepressant tablets coating manufacturing process. The coating process was identified due to the utilization of toxic ingredients and hazardous materials during the coating solution preparation and during the coating application. In addition, lost time and productivity were identified in the process. The tool selected to perform a Lean and Safe Manufacturing Process in this coating process was 6S (Sort, Set in Order, Shine, Schedule, Score and Safety). Contributions, like the creation of a system that will be used to maintain an organized, clean, safe, and efficient setting that enables the highest level of value-added performance, were achieved during the 6S event implementation. In addition, a decrease in cycle time, in operators needed in the process execution, and minimization of injuries risk, were very important contributions achieved. Key Terms - 6S, Coating Process, Lean and Safe Manufacturing, Manufacturing Process.Item Quality Improvement in a Medical Device Manufacturing Process Applying Six Sigma Tools(Polytechnic University of Puerto Rico, 2009) Rondón Nieves, Luis Daniel; Zárate, PatriciaAbstract - The current manufacturing process of a medical device product has great opportunities on scrap percent reduction, which has been impacting the material and labor costs of the product, as well as in defects per million (DPMs) reduction, to improve the quality of this product. The current scrap percent has been affecting the production yield and complaints from clients (surgeons) have been increasing during the last Fiscal Year. The Six Sigma structure DMAIC: Define, Measure, Analyze, Improve, and Control, will be the key for the success of this project. The expected benefits are the evaluation, recommendation, and implementation of any opportunity of quality improvement that results in a positive impact to the clients at a low cost of production for the company. The main research contribution is that this project provides the customers (surgeons and their patients) an instrument that always actuate as established in the specifications to save humans lives. Key Terms Medical Devices, Process Optimization, Quality Improvement, Six Sigma.Item Application of Design of Experiment to Demonstrate Equivalency of Two Multi Layer Compression Process for an Extended Release Tablets Product(Polytechnic University of Puerto Rico, 2009) Carrión Vega, Jaime; Nieves Castro, Rafael A.Abstract ― A design of experiment (DOE) was performed to a multi layer compression process that is going to be transferred from facility A to facility B. This study demonstrates and compared the equivalence of the compression process of a non-validated process site with a validated process from the original site. The relevance of this project is to demonstrate the equivalence of the process to ensure the robustness, and quality of the product. During the compression process, the weight of multiple stages, thickness, and hardness were collected in both machine. The data collected was analyzed using One-Way-ANOVA and Kruskal-Wallis test. Based on the results obtained from the data, it was concluded that both multi layer compression process are equivalent. Key Terms ― Design of Experiment, Extended Release Tablets, Multi Layer Compression Process, One – Way – ANOVA.Item Cycle Time Reduction using Lean Manufacturing Techniques for a Solid Pharmaceutical Product(Polytechnic University of Puerto Rico, 2009) Ocasio Ortiz, Ángel; Pons Fontana, Carlos A.Abstract ⎯ The purpose of this project was to demonstrate that the Lean Manufacturing techniques could be applied to a Solid Pharmaceutical Product in order to reduce the cycle time. During the year 2007, the Solid Pharmaceutical Product studied had 52 days of cycle time. The goal is to reduce the cycle time 25% or to 39 days. Lean Manufacturing tools used in this project was the process map to develop the required knowledge of the manufacturing process and the Value Stream Mapping where the values added and non-values added activities were identified. A Multidisciplinary team, essential for creation and implementation of new ideas, a list of improvements was generated and weighted for prioritization. This prioritization matrix is the foundation to start the implementation of improvements. After the Multidisciplinary team implemented the short term improvements in the Manufacturing Area, it was observed that the Product Cycle time decreased to 37 days in the third quarter of the 2008. After completion of the study, it was proved that the Lean Manufacturing techniques can be applied to a Solid Pharmaceutical Product and can radically reduce the cycle time. Key Terms ⎯ Kaizen, Value add (VA), Value Stream Map and Waste (muda).Item Application of DMAIC Methodology to Improve the Utilization of an Industrial Glassware Washer System in a Biopharmaceutical Industry(Polytechnic University of Puerto Rico, 2009) Colón Santiago, Cindy; Pons Fontana, Carlos A.Abstract ⎯ This article describe how the problem solving approach of Define, Measure, Analyze, Implement and Control (DMAIC) is applied to increase the utilization of an industrial glassware washer system in a Biopharmaceutical Industry. The application of this methodology results in a deep understanding of the cleaning process. Sources of variation were identified and a root cause analysis conducted allows for the identification of potential solutions as well as selection and implementation of improvements. The implementation of improvements in the control phase reflect reductions in the amount of cleaning loads required to satisfy manufacturing needs on a weekly basis, reducing in 40% the amounts of loads,increasing by 20% the utilization of the cleaning system and providing tools to the support area staff that will allow them to have a better understanding of the logistic involved along the cleaning process. Key Terms ⎯ DMAIC methodology, cleaning system utilization.Item Improvement of Contact Lens Field Complaint Rate Using the DMAIC Approach(Polytechnic University of Puerto Rico, 2009) Pietri, Emil A.; Pesante Santana, José A.Contact lenses are susceptible to a defect call “tearing”. This is common but seldom condition detected in the field by the customer. The manufacturing process of a contact lens is a very precise method of combining an injection molding processes with a chemically bonded monomer. The liquid monomer is automatically placed between two half’s of plastic injected molds then forming the lens ,subsequent process of curing ,de-molding , hydration and packaging would form the final product for sale. The purpose of this study is to demonstrate that the application of the 6 sigma DMAIC approach to problem solving would provide a methodical and enriched conclusion to the root cause determination of contact lens “tearing” thus reducing the defect rate, subsequently customer complaints. Key Terms - Define, Measure, Analyze, Control