Manufacturing Engineering
Permanent URI for this collectionhttps://hdl.handle.net/20.500.12475/53
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Item Improve Vision System Seal Presence Inspection(Polytechnic University of Puerto Rico, 2024) Luciano González, Anaisha I.; Nieves Castro, Rafael A.The sterile packaging of implantable medical devices is crucial for ensuring patient safety, preventing post-operative infections, and maintaining the integrity of the device until implantation. Given that these devices are placed within the body, contamination with harmful microorganisms can lead to serious complications, including implant failure and life-threatening infections. Sterile packaging acts as a barrier against pathogens, maintaining the sterility of the device during storage and transportation. Vision systems play a critical role in the sterile barrier inspection of implantable medical device packaging by ensuring the integrity and quality of the packaging, which is essential to maintaining sterility. In the manufacturing plant, inefficiencies in the packaging process, particularly in seal inspection, result in compromised product quality and potential contamination risks. Manual inspections and outdated quality control systems are prone to human error, leading to undetected seal defects, rework, and product recalls. In addition to the sterility issue, in the specific case being studied through this project, the sealing inspection inefficiencies create a productivity burden and operators’ burnout due to the extensive inspections. Key Terms - DMADV Method, Seal Inspection, Vision Systems.Item Revitalizing A Small Restaurant through Lean Manufacturing Practices(Polytechnic University of Puerto Rico, 2024) Morales Lugo, Gabriel A.; Morales Morales, José AlbertoThis project aims to improve the structural integrity of hamburger patties in a food truck setting. Several preparation methods were tested to determine their impact on patty cohesion, including refrigerated vs. frozen storage, liquid ingredient proportions, the timing of salt addition, and the use of cheese as a topping. The Mann-Whitney U test and Kruskal-Wallis test were used to analyze the results, with effect size calculations providing further insight into practical significance. While some differences were not statistically significant, effect size analysis showed meaningful variations, particularly in the timing of ingredient addition and storage methods. The findings offer practical recommendations for optimizing patty preparation processes to improve product quality. Key Terms - Effect Size, Food Truck, Hamburger Patty, Structural Integrity.Item Warehouse Design and Usage, Inventory Control System, and Material Handling Logisticsfor a Vertical Transportation Company(Polytechnic University of Puerto Rico, 2024) Vázquez Díaz, Brian A.; González Miranda, Carlos J.When it comes to delivering an ideal service based on quickness and effectiveness, the main or only focus does not only depend on the customer service, but also, on what, when, where, why, and how background operations work to ensure the availability to provide a service of excellence. In some particular cases, service problems might arise due to misuse of warehouse space, a lack of an inventory control system, and a blurred vision of an opportunity for material handling improvements. Executing a complete analysis where concepts of lean manufacturing, and six sigma are implemented to facilitate the performance of the warehouse and inventory logistics with the appropriate equipment to improve the service offered. From identifying and organizing inventory, to designating areas in the warehouse floor space, to appropriate equipment for handling materials, everything is for a continuous and consistent business where the values of reliability, security, and efficiency are pillars in the company’s vision. Key Terms — Inventory Control System, Lean Thinking, Material Handling Automation, Six Sigma.Item Implementation of a Change Control Process in a Pharmaceutical Industry(Polytechnic University of Puerto Rico, 2024) Ramos Feliciano, Paola C.; Nieves Castro, Rafael A.The pharmaceutical industry is monitored by the highest regulatory bodies such as the Food and Drug Administration (FDA) and other agencies to ensure compliance with Good Manufacturing Practices (GMP) and Good Documentation Practices (GDP). The quality of the product is demonstrated through data generated within the process and supporting documentation. The data should demonstrate consistency, accuracy and completeness for data integrity. At the same time the equipment, process and systems should be validated for the intended use. This project focuses on the implementation of a change control in a validated system emphasizing in the required documentation to demonstrate the system has the capacity to function as it is intended and continues to meet regulatory standards. Additionally, the project provides a solution to a problem that has the potential to have data integrity issues. Key Terms ⎯ Change Control, Computer System Validation, Pharmaceutical Industry.Item Reducción de Costos con Impacto Ambiental Positivo: Un Enfoque Sostenible en la Industria Manufacturera(Polytechnic University of Puerto Rico, 2024) Hernández Rosado, Manuel C.; Nieves Castro, Rafael A.Esta investigación se centra en la implementación de prácticas sostenibles para optimizar la eficiencia energética y reducir costos en una industria manufacturera. El objetivo principal es explorar estrategias innovadoras que mejoren la optimización de procesos, incorporen tecnologías verdes, gestionen eficientemente los residuos y utilicen los recursos naturales de manera responsable. Además, el estudio examina la viabilidad de iniciativas de energía renovable, como la integración de fuentes de energía limpias y sistemas avanzados de reciclaje, orientadas a mejorar tanto la sostenibilidad económica como la ambiental dentro de la operación manufacturera. El enfoque no solo busca lograr una reducción de costos a largo plazo, sino también reforzar la responsabilidad social corporativa y contribuir al desarrollo de modelos de producción más amigables con el medio ambiente. Al emplear tecnologías y procesos sostenibles, la investigación demuestra cómo las industrias manufactureras pueden disminuir significativamente los gastos operativos mientras mejoran su huella ecológica, lo que lleva, en última instancia, a una práctica industrial más responsable y sostenible. Palabras Claves - Eficiencia Energética, Energía Renovable, Gestión de Residuos, Industria Manufacturera, Optimización de Recursos, Prácticas Sostenibles, Reducción de Costos, Responsabilidad Social Corporativa, Sostenibilidad Ambiental, Tecnologías Verdes.Item Qualification of the Cold Chain System in Drug Logistics(Polytechnic University of Puerto Rico, 2024) Otero Torres, Yailyn; Nieves Castro, Rafael A.Distributions Centers for pharmaceutical products have experienced significant changes in recent years in terms of the cold chain, adapting to new social, economic, and technological structures. The main objective of this process is to maintain a constant cold temperature of refrigerated pharmaceutical products, which requires maintaining a refrigeration specification of 2°C to 8°C. This article aims to use DMAIC tools to help us ensure that deliveries from more distant routes to different customers consistently meet the required temperatures from their departure from the distribution center to delivery to the customer. Key Terms - Cold Chain System, Distribution Centers, DMAIC Method, Pharmaceutical Products.Item Improvement and Standardization of the Remuneration Process of Engineering Lecturer Professors(Polytechnic University of Puerto Rico, 2024) Samó Velázquez, Yahira M.; Nieves Castro, Rafael A.Human beings invest plenty of time carrying out various tasks for an employer or company to generate a salary. Salaries must satisfy the personnel who provide services to earn income [1]. After conducting a study on the remuneration processes of lecturers at a post-secondary institution using the DMAIC methodology, it was determined that the personnel in charge of the processes need to standardize it to satisfy professors’ needs, such as counting a highly efficient. This standardization should come into force for the semester from August to December 2024 and will take 30 days to 3 months to be fully implemented. According to the research, the time taken by the remuneration process will decrease from 4 weeks and five days to 14 days, and the receipt of the salary will go from one month after the professors sign the contract to 15 days after signing the contract. Key Terms - DMAIC method, Improvement Remuneration, Standardization.Item Optimization of Shear Testing(Polytechnic University of Puerto Rico, 2024) Acevedo Liceaga, Wilfredo; González Miranda, Carlos J.This research project focused on improving shear testing processes. This project aims to implement a new system that performs shear testing without destroying the piece, thus reducing the scrap percentage. The DMAIC methodology was used to enhance the shear testing process. DMAIC is a concept that measures defects in business processes and improves profitability. DMAIC stands for the process's five main steps: Define, Measure, Analyze, Improve, and Control. This research seeks to improve the measurement process of shear tests. This is important for the process because it will reduce scrap, decrease the error percentage when measuring shear in each piece that undergoes welding processes, and provide a more accurate value, thus improving quality. The DMAIC methodology provides a structure and tools to enhance a process by optimizing and stabilizing the business process. In this case, it would involve eliminating destructive tests and reducing scrap percentage due to shear tests. Key Terms — Optimization, Residential Breakers; Shear Test; Welding Process.Item Design and Implementation of a Green Light Signal Process for Regulatory PMO Team(Polytechnic University of Puerto Rico, 2024) Luciano González, Virginia; Nieves Castro, Rafael A.The Project Management Office (PMO) Regulatory Team, manages regulatory projects that include in the scope all countries globally that can import and distribute their products. The Master Regulatory Schedule (MRS) is prepared with the countries’ outcome to provide visibility to the Franchise and Supply Chain (SC) of the projects that are in the process of being implemented. Challenges for Supply Chain to provide accurate data into the Master Regulatory Schedule and for countries to review the data provide and align dates have been evaluated to identify the risks for restricted countries that cannot receive the previous product after submitting or approving the new product. The main goal is to achieve supply continuity in all countries and avoid any disruptions in product supply by implementing a Green Light Signal. The Project Management Office team started gathering feedback to improve the process, reduce workload, identify priorities, and avoid and mitigate risks. Key Terms ⎯ Green Light Signal, PMO, Restricted countries, Supply Continuity.Item Understanding and Reducing the 709 Equipment Variability to Validate K3/K4 with an Alternate Resin at the Polytechnic University of Puerto Rico(Polytechnic University of Puerto Rico, 2024) Rivera Rodríguez, Víctor M.; Avilés Segundo, Iván M.This project is focused on the quality assurance hurdles in the injection molding processes of part no. FYA1470, encountered while validating the K3/K4 product using a substitute resin required by the customer. Utilizing the Define – Measure – Analyze – Improve – Control (DMAIC) methodology, the project successfully pinpointed and improved multiple root causes affecting the process. Critical interventions included fixing the resin injection barrel’s temperature controller's malfunction and errors in the measurement program, which led to a reduction in process variability and an enhancement in capability indices. Among the six Critical to Quality (CTQs) dimensions, two did not align with customer specifications, previously defined with the former resin. A CTQ is a characteristic/factor that can affect the product/process quality [1]. On the other hand, as a result of applying the DMAIC methodology, it was determined that CTQ2's performance remained consistent between Operational Qualification (OQ) and Performance Qualification (PQ) phases with the new resin, whereas CTQ3 exhibited marked improvement. To ensure ongoing process stability, control measures were implemented, notably the integration of temperature monitoring into the Preventive Maintenance (PM) and Calibration schedules. A good PM and Calibration program will guarantee a good functioning reducing the risk of unexpected failures [2]. Key Terms - capability indices, Critical to Quality (CTQs) dimensions, DMAIC methodology, process variance.