Manufacturing Competitiveness
Permanent URI for this collectionhttps://hdl.handle.net/20.500.12475/52
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Item Implementation of an Optimized Electronic System in a Manufacturing Industry(Polytechnic University of Puerto Rico, 2024) Garcia Santos, Lyannis M.; Morales Morales, José AlbertoThe pharmaceutical industry plays a vital role in global health, improving people’s wellbeing, so time delivery is critical. That is why companies are implementing automation in their processes. Hence, this research project intended to enhance productivity within a pharmaceutical company by implementing an optimized electronic system. The focus was to keep the deviation rate at 7% or below and keep consistent cycle times. Data from 2022 was analyzed, and it exhibited high deviation rates and cycle times that were not consistent, indicating the need for improvement. Upon the implementation, results showed that the deviation rate remained below 7%. In addition, cycle times remained stable and low. A comparison of pre-and post-implementation data revealed significant improvements in both deviation rates and cycle times. However, continuous monitoring is crucial to validate the sustainability of these improvements and to identify possible trends and further improvements in the process. Key Terms - Cycle Time, Deviation Rate, Manufacturing Electronic Systems, Process Improvement.Item Streamlining Manufacturing Operations Through Lean Six Sigma and Industrial Automation(Polytechnic University of Puerto Rico, 2023) Rivera Sánchez, Yaití; Morales Morales, José AlbertoThis pharmaceutical packaging design project integrates Lean Six Sigma principles and industrial automation to optimize a manual intensive process. Focused on loading/unloading, visual inspection, and palletizing, the improvements include automated systems, such as cameras for inspections and robotic lifts for loading and palletizing. The study reveals a substantial reduction in cycle time, from 91 to 72 minutes, showcasing a 20% improvement. Statistical analysis indicates significant results (p < 0.001), validating the effectiveness of the enhancements. The streamlined process aligns with Lean principles, emphasizing efficiency, waste reduction, and improved quality control. The project contributes to operational excellence, offering a competitive edge in the pharmaceutical industry. Key Terms ⎯ Cycle Time Reduction, Industrial Automation, Lean Six Sigma, Pharmaceutical Packaging.Item The Impact of a Quality Management System (QMS) on the Scientific Software Development Process – A Case Study of a Small Company(Polytechnic University of Puerto Rico, 2023) Nieves Cruz, Sherly Ann; Morales Morales, José AlbertoDeveloping software for scientific applications is an intricate and multifaceted process that requires meticulous attention to detail. Implementing a QMS to provide a comprehensive framework that integrates all quality processes to mitigate inefficiencies such as waiting times and over-processing waste is essential. This study evaluated the effectiveness of the QMS and its potential impact on this particular software development process, employing statistical analysis. Historical data was compared with simulated data to assess proposed optimizations before and after implementation. The statistical analysis included a range of techniques, such as ANOVA, Hypothesis Testing, Regression Analysis, Capability Analysis, and others. It demonstrated potential significant improvements across all evaluated variables in the final software product, including deviations during validation, change controls, time to complete a product (hours), and corresponding labor costs (dollars). A QMS provides a foundation to prevent quality issues, improve customer satisfaction, reduce rework costs, and boost profits. It's a smart investment for companies seeking measurable benefits. Key Terms - Quality Management System (QMS), Quality Practices, Scientific Software Development Quality Control, Scientific Software Productivity.Item Pull System for Material Replenishment in Manufacturing Sunshine Meds Design(Polytechnic University of Puerto Rico, 2023) Rivas Pagán, Samelia M.; Morales Morales, José AlbertoThis project evaluates the material replenishment for manufacturing lines in Sunshine Meds Company who prepares medical devices kits in a manufacturing cleaning room. Opportunities were found looking into the material handles replenishment process like a waste of time and waiting time in stations while raw materials are supplied. In this industry, the product is a medical device containing raw material with a shelf life and expiration date. The problem statement is the following: due to a lack of organization, there is a high time consumption to complete a replenishment cycle, excess inventory on the manufacturing floor, and no signals to replenish material, causing a lack of material handler flexibility to serve different manufacturing lines. Designing a Kanban system as a part of the replenishment process using two types of signals, a bin system and an inventory level system could solve the higher volume of raw material in the clean room. Key Terms ⎯ DMAIC, Lean Methodologies, Pull System, SIPOC, Six Sigma.Item Desarrollo de Matriz de Complejidad y Mejoras a la Matriz de Destreza para Reducir la Fatiga en el Área Laboral(Polytechnic University of Puerto Rico, 2023) Ponce Balaguer, Joan; Morales Morales, José AlbertoLa fatiga en el área laboral o los riesgos ergonómicos se deben principalmente a la ejecución de una estación de trabajo por un tiempo prolongado sin tener variaciones en las tareas que ejecuta. Los riesgos ergonómicos son la probabilidad de desarrollar un trastorno musculoesquelético debido al tipo e intensidad de actividad física que se realiza en el trabajo [1]. El riesgo al que se expone un trabajador cuando está principalmente en estaciones de alto impacto depende de tres factores: la magnitud del riesgo, la duración y la frecuencia de exposición [2]. Para evitar o disminuir cualquier riesgo musculo esqueletal es sumamente necesario realizar un plan de rotación, en el cual el empleado se mueva cada dos a cuatros horas de estación de trabajo. Esto, permitirá disminuir la duración de la exposición de riesgos asociados con los trastornos musculoesqueléticos como lo son: mantenimiento de posturas forzadas, levantamiento de cargas, realización de movimientos repetitivos o exposición a vibraciones. Términos Claves - Ergonomía, Matriz de Complejidad, Matriz de Destreza, Rotación.Item Standardization Times in a Blending (Flex 2 Unit Operation) Manufacturing Process(Polytechnic University of Puerto Rico, 2023) Acevedo Colón, Gabriel; Morales Morales, José AlbertoThe continuous evolution in standardization, digitalization, and changes in the ways of working in manufacturing in the pharmaceutical industry and the increase in production for product X by 2023, has made it necessary to study the work process and standardize the blending production unit of the Flex 2 production area. The Flex 2 area is dedicated to a single product only. For the preparation of the drug, the area of Flex 2 performs 2 different types of API mixing, since the drug in its final stage of compression is a Bi-layer tablet. The blending process requires standardizing the number of operators needed to execute the batches and the number of batches that can be manufactured in the Flex 2 Blending unit. In 2022, a total of 610 batches were processed and the average batch cycle time was 7.0hrs. Key Terms - Blending, Cycle Time, Lean Manufacturing, Standardization Times.Item Implementación del Parámetro Tolerancia de Proceso en el Certificado de Calibración a Instrumentos Críticos del Área de Liofilización a Través del CMMS para Reducir las Investigaciones(Polytechnic University of Puerto Rico, 2023) Vega Colón, Daileen; Morales Morales, José AlbertoLos parámetros establecidos en los procesos de calibraciones son un factor crítico en la manufactura de productos farmacéuticos. A raíz de la alta incidencia de investigaciones para el departamento de calibración, se identificó la ausencia del parámetro tolerancia de proceso en los instrumentos críticos del área de liofilización. El estudio buscó disminuir la incidencia de la irregularidad originada por instrumentos fuera del parámetro establecido, mediante la implementación de un nuevo parámetro amplio acorde al proceso. Para poder establecer el parámetro, se realizó un análisis de los instrumentos críticos careciendo del parámetro, junto al equipo de operaciones técnicas, se estableció el parámetro para 87 instrumentos. Posteriormente se procedió a implementar el parámetro al CMMS, que es el sistema computadorizado para el manejo del mantenimiento de equipos. Términos Claves - CMMS, Instrumentos de calibración, Investigaciones, Liofilización, Parenterales, Tolerancia de Proceso.Item Mejoras Al Diseño Establecido en el Proceso de Empaque para la Industria Biofarmacéutica con el fin de Minimizar Errores Humanos(Polytechnic University of Puerto Rico, 2022) Vázquez Santos, Yelitza; Morales Morales, José AlbertoEn una línea de manufactura, el 83.3% de los operadores concuerda con que el proceso de documentación es complejo, lo que aumenta la incidencia de errores humanos. El propósito de este estudio es identificar posibles modificaciones para evitar los errores humanos en la documentación del proceso, disminuir los retrabajos, mejorar la calidad, eliminar el desperdicio, reducir el tiempo de entrega y los costos totales. La mejora impacta la arquitectura del diseño de documentación en el sistema para algunas presentaciones en el área de empaque de las líneas de inspección. De igual forma, en 3 meses se generaron 7 desviaciones por errores humanos. Los resultados, luego de la implementación, mostraron que el área de oportunidad que existía al momento de documentar y cometer algún tipo de error humano en el proceso disminuyó. Hubo una mejora de 35 minutos promedio en el proceso de documentación entre los tres turnos de trabajo. Palabras Claves – Errores humanos, Mejoras, Productividad, Simplificación de procesos.Item Improvement in the Visibility of Nonconforming Product Inventory and Reduction(Polytechnic University of Puerto Rico, 2022) Ramos Galarza, Vivian A.; Morales Morales, José AlbertoOne of the major problems reported in a company is the Nonconforming product inventory, reducing the availability to use space for new production lines and storage of conforming product. Company wants to understand why the nonconforming products are exceeding the expected product disposition closure date, why the hold cages are full causing difficulty of locating a particular nonconforming production order in the storage areas. There are key elements of information to understand the actual status of nonconforming inventory. Therefore, the implementation of an optimized NC Monitoring Report system, through the using an ERP System, helps to prioritize Product Dispositions execution, reducing the aging of inventory and improving the allocation of resources to value added activities. After evaluation of current NC Monitoring Report system and proposed new NC Monitoring Report systems, waste removal in the cycle time is reduced from 223 minutes to 31, which represents a reduction of 86%. Key Terms ⎯ Disposition, Nonconformance, Nonconforming product, Product Inventory.Item Fiber Drums Reduction in Weighing & Dispensing Manufacturing Process(Polytechnic University of Puerto Rico, 2022) Rosa, Diangie M.; Morales Morales, José AlbertoAchieving overall efficiency within the manufacturing processes is the key goal among many organizations. Reducing waste enables manufactures to save money and take production up a notch. LEAN manufacturing and DMAIC are tools that can be helpful to reduce costs by removing waste within an organization, increasing productivity, and addressing environmental impacts. In search of improving the manufacturing PV, opportunities for improvement were identified in the weighing & dispensing process that would bring multiple benefits. Nowadays, companies’ principal goals are focused on costs, waste reduction and reduce production time. By implementing dedicated containers for a specific process manufacturing area has been able to reduce generated waste, reduce yearly costs and improve cycle time of processes. Because less is more. Key terms – Capacity, Continuous'Improvement, Cost Reduction, Waste Reduction.