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 Recomendaciones para la Mitigación de Eventos de Control de Plagas en Áreas de Manufactura de Industria Farmacéutica Ubicada en Gurabo, PR(Polytechnic University of Puerto Rico, 2022) Rodríguez Santiago, Carlos Xavier; Pons Fontana, Carlos A.Debido al alza en eventos de control de plagas en una industria farmacéutica ubicada en el área de Gurabo es que se realizó esta investigación. La palabra plaga significa cualquier animal o insecto no deseado que impacte el área de manufactura.Se utilizó la metodología de Lean para identificar áreas de oportunidades para mitigar los eventos de control de plagas en el área de manufactura. Este método DMAIC tiene cinco pasos para mejorar sus procesos, mejorar su eficiencia o simplemente implementar mejoras a áreas en deficiencia (control de plagas), en otras palabras, buscan mejorar las buenas prácticas de manufactura. Se hizo un análisis del proceso de los eventos del control de plagas y basado en esta información, se hicieron recomendaciones para mitigar eventos de control de plagas en el futuro. Palabras Claves –Buenas Prácticas de Manufactura, GMP, Mantenimientos Preventivos y PM.Item Paperless Harness/Cables Fabrication(Polytechnic University of Puerto Rico, 2022) Torres Agosto, Brenda; González Miranda, Carlos J.This project focused on Paperless Harness/Cables Fabrication for Documentation Control in an aerospace company. Documentation control improves paperwork handling, the gathering and filling of all the documentation required for the Harness/Cable Build. In order to improve documentation handling, the Lean Manufacturing methodology will be used. Lean Manufacturing’s goal is to eliminate waste—the non-value-added components in any process. This research will be focused on eliminating waste using the Lean Manufacturing 5S principle to improve the cleanliness and organization of the workspace. 5S concepts include the following definitions: sort, simplify, shine, standardize, and sustain. This research seeks to implement the Paperless Work Order Traveler of Harness/Cables Fabrication. This is important for the process because it will add Fabrication status visibility to the internal customer, reduce/eliminate the waste of paper in the fabrication area, reduce/eliminate the loss of documentation, standardize the process, and improve the space in the work station, clean area. Lean Manufacturing methodology brings structure and tools to improve a process by standardizing and improving the process in, in this case, paperless Harness/Cables Fabrication in an aerospace company. Key terms- harness/cable fabrication, paperless, standardization, work ordersItem Increase of Manufacturing Process Output(Polytechnic University of Puerto Rico, 2020) De Jesús Flores, Yeisha; Nieves Castro, Rafael A.Haemonetics Puerto Rico, a medical devices manufacturing site of blood filters, identified that approximately the 11% of the monthly plan of the manufacturing line #3 cannot be made using the available manufacturing time of the line. The objective of this project is to increase in at least 20% the manufacturing line output by identifying and eliminating the wastes in the manufacturing process of line #3. To achieve this goal, the DMAIC methodology will be used to identify the possible root causes and improve them adequately. After following DMAIC methodology and provide improvements, the line output increased in a 22%, which means that the line will only require 37 shifts per month to complete the manufacturing plan from the 40 shifts available. With this improvement, line #3 now can comply with the monthly plan. Key Terms ⎯ Filter manufacturing, lean manufacturing, process output, Six SigmaItem 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 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 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 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 Puerto Rico Water and Sewer Service Calibration Operation Cost Reduction(Polytechnic University of Puerto Rico, 2013) Navarro Carrillo, Erica; Nieves Castro, Rafael A.For the last few years, the economy of Puerto Rico has been negatively affected, increasing the operational cost of the industries in the Island. In addition, regulatory agencies have been increasing their requirements and conditions that enforce activities to ensure environmental protection for a cleaner, healthier environment, and protect the public health. Companies focus on production efficiencies and often drive attention from inefficiencies in their calibration programs, promote practices that can significantly increase cost and put quality at risk. Under this panorama the calibration department for the Puerto Rico Water and Sewer Service Industry determine to look into the process, following managerial concept that combined Lean Manufacturing techniques and Six Sigma strategies. This project has been developed under the Lean Six Sigma principles and using DMAIC five-step approach, in order to identify opportunities to enable the company to reduce overall cost and gain efficiencies and breakthrough the calibration department operation cost. Key Terms - Calibration Operation, DMAIC, Lean Six Sigma, Water and Sewer Service Industry.