Manufacturing Competitiveness
Permanent URI for this collectionhttps://hdl.handle.net/20.500.12475/52
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Item Manejo en la Frecuencia de los Mantenimientos Preventivos “runtime” y Fijos del Departamento de “Downstream”: “Geldipping, Coating & Printing”(Polytechnic University of Puerto Rico, 2023) Velázquez Velázquez, Nikyshaliz; Nieves Castro, Rafael A.McNeil Healthcare es una farmacéutica encargada de manufacturar Tylenol para tratar molestias y dolores. Durante los pasados 3 años se encuentra atravesando dificultades con el cumplimiento de los planes de producción y la alta demanda del cliente, ante la emergencia del COVID-19. Se identificó que los equipos de manufactura estaban siendo poco eficientes, generando grandes cantidades de desperdicios y periodos extendidos de “downtimes”, a pesar de los mantenimientos preventivos fijos y “runtime” que se realizan con regularidad. Los mantenimientos preventivos son ajustes, inspecciones, reemplazo de piezas, limpieza y recomendaciones del fabricante programados para mantener eficiente y operable el equipo. Utilizamos la metodología DMAIC para desarrollar e implementar un plan de acción y resolver el problema. A través de los datos recopilados y la ayuda del personal técnico, se identificó que se debía ajustar la frecuencia de ambos mantenimientos para obtener mejor eficiencia de nuestros equipos y cumplir los requerimientos del cliente. Términos claves - Mantenimientos fijos, Mantenimientos preventivos, Mantenimientos “runtime” y Método DMAIC.Item Design and Implementation of a Warehouse Management System(Polytechnic University of Puerto Rico, 2023) De León-Vélez, Lynette D.; Nieves Castro, Rafael A.A Warehouse Management System (WMS) is software used for Inventory Management (IM) to manage and control daily warehouse operations/transactions. This covers the transaction of all materials from the receiving stage until delivery. A WMS is essential for Supply Change Management and offers a full range of a company’s inventory. This involves all on-site transactions as well as activities related to in transit. The pharmaceutical/medical devices industry depends on a reliable WMS to better understand how to manage all the transactions regarding a company's inventory—having this kind of tool allows a better understanding of the life cycle of the inventory since it is received at the site until final delivery is crucial for the company’s operation. A WMS was designed and implemented to cover this activity, using a define-measure analyze-improve-control (DMAIC) activity. Based on the outcome of this activity, Upper Managers saw an improvement in their warehousing operations in terms of efficiency and effectiveness. Key Terms ⎯ DMAIC, IM, process improvement, WHS.Item Aplicación de Metodología DMAIC-Seis Sigma para Mejorar el Proceso de Almacenaje de una Compañía Distribuidora de Accesorios de Equipos Electrónicos(Polytechnic University of Puerto Rico, 2023) Cartagena Rivera, Kevin A.; Nieves Castro, Rafael A.Este proyecto contiene la propuesta de trabajo para el mejoramiento del área de almacén de una empresa de distribución de accesorios para equipos electrónicos como celulares, tabletas, etc. y el estudio se centrará en la reubicación y organización de la mercancía y estanterías para almacenaje teniendo en cuenta su posición dentro del área, accesibilidad y facilidad para disponer de los materiales en el momento en que se necesiten. La empresa se caracteriza por la búsqueda de nuevos métodos que le permitan implementar un mejor control en sus procesos como la recepción, el almacenamiento y movimiento de materias primas, así como el control de la mercancía existente dentro del almacén. Esto sirve para manejar un inventario real en un tiempo efectivo, permitiendo proyectar y planificar órdenes de producción de un producto determinado anticipándose a la demanda del mercado obteniendo garantía en el cumplimiento hacia los clientes. Con esto se busca organizar, planear, ejecutar y controlar esta tarea aprovechando lo aprendido y generando soluciones efectivas a estas oportunidades de mejora detectadas en esta empresa. Términos claves ⎯ almacén, DMAIC, inventario.Item Implementation of Operational Excellence’s Framework on a Local Pizzeria(Polytechnic University of Puerto Rico, 2023) Agosto Sherman, Kenneth; Nieves Castro, Rafael A.During these last years, due to the economic impact that has arisen in Puerto Rico, all industries have sought to manage, control, and efficiently use their inputs. It is no surprise that this has impacted a local pizzeria, where they are seeking to implement improvements to ensure quality, control costs and satisfy customers and thus make them loyal customers and retain them. Next, we will use a tool widely used in practically all pharmaceutical companies, medical device factories, and combined product factories. Tools covered under Lean and Six Sigma, help critical and strategic thinking. A standard procedure was implemented and helped align everyone to create a final product using the same procedure. Everyone understood how to follow it, which was easy to implement. It will also be used to train new employees and leave the product with the quality of a pizza maker with more years of experience more easily. Key Terms - Lean, Pizza, Six Sigma, Standard Operation Procedure.Item Improving the Cleaning Certification Process in the Manufacturing Area(Polytechnic University of Puerto Rico, 2023) Candelaria Juarbe, Isis N.; Nieves Castro, Rafael A.By addressing the shortcomings and inefficiencies in the present Cleaning Certification procedure used by biotechnology manufacturing companies, this project seeks to modernize and streamline it. The technique experiences lags and disconnects from vital systems like Manufacturing Execution System (MES) and Laboratory Information Management System (LIMS), impacting product release timing. The Define, Measure, Analyze, Design, Verify (DMADV) methodology is used in this project to thoroughly comprehend the current process, gather and analyze data, and create a digital platform that smoothly combines Manufacturing Execution System (MES) and Laboratory Information Management System (LIMS). The initiative aims to increase operational effectiveness, decrease waste, and maintain regulatory compliance by speeding up sample testing and automating the Certification process. A new age of excellence in biotechnology manufacturing is ultimately intended, which will redefine industry norms. Key Terms - Biotechnology Industry, Cleaning Certification, DMADV Methodology, and Lean Manufacturing.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 Workflow Management in the Batch Record Review Process(Polytechnic University of Puerto Rico, 2022) Velázquez Vázquez, Michelle; García Sandoval, Maria M.The review of Batch Records creates a story of the materials, manufacturing, and packaging involved in the production of biopharmaceuticals. The Master Batch Record details who, when, where, and how each process stage is carried out and how much of a product is produced. Most pharmaceutical companies need help to check batch data in time to provide medications to clients. However, a prolonged processtime affects how quickly goods must be made available to the public. As a result, reviewing batch records is a laborious process that mainly occurs afterward. For the manufacturing purification processes of a chromatography column, viral inactivation filtration, viral filtration, ultrafiltration, diafiltration, and bulk filling for a high cholesterol drug, this project assesses the viability of an incremental batch record review in real time. The DMAIC technique was used in this project's study to show how the queue time is decreased. The value-added time is increased, and other advantages. Key Terms ⎯ Batch Record Review, Lead Times, Process Improvement, Workflow.Item Feasibility Study of Proposed Manufacturing Layout Re-design to Improve Process Capacity and Reduce Cycle Time of a Downstream Operation of Product A(Polytechnic University of Puerto Rico, 2022) Aponte Santiago, Lyanne M.; Nieves Castro, Rafael A.Lean Six Sigma tools and methodologies are widely used in today’s work environments. The use of a Lean Six Sigma approach provides organizations more flexibility and efficiency to improve their competitiveness. At the present time, with the high market changes environment, is crucial for industries to improve their processes to fulfill their customers’ needs. One key area for Manufacturing Operations is their production layout design. This article will discuss the use of DMADV (Define, Measure, Analyze, Design, & Verify) methodology to complete, and evaluate a feasibility study of a manufacturing layout re-design proposal. The project concluded that the proposed manufacturing layout re-design will represent a reduction of approximately 29-36% of the current process cycle time and represent a potential increase in production capacity of approximately 15-25%. These benefits identified during the feasibility study activities can lead to improve the company’s competitiveness and obtain financial benefits. Key Terms ⎯ Cycle time, DMADV, Lean, Process Capacity.Item Optimization in the Account Registration Process in Automated Equipment(Polytechnic University of Puerto Rico, 2022) Amador Cordero, Luis R.; Nigaglioni, RolandoOver the years technology has increased in the manufacturing areas. Companies have moved to obtain automated equipment for the manufacture of their products. In the pharmaceutical industry, this equipment has been implemented to increase production. The equipment is managed by operators, and each operator must have access to them. The pharmaceutical industry in the US is governed by the FDA (Food and Drug Administration), and it has guidelines to ensure the proper use of this equipment and those who use it (21 CFR part 11). During this project, improvements were made to the process of creating accounts for automated teams, where positive results were obtained for the company. Thus, creating a standardized system with quality controls. In addition, the time it took a staff to create an account was reduced from 82 minutes to 51 minutes in this process. For the development of this project, the Six Sigma methodology and its DMAIC tool were used to determine the defects of the process and thus achieve the main objective. Key Terms ⎯ Dmaic, FDA, Optimization, Six Sigma.Item Designing a Standardized Process Flow for Regulatory R&D Service Center: A Design for Lean Six Sigma DMADV Case Study(Polytechnic University of Puerto Rico, 2022) Molina Cordero, Jonathan M.; Nieves Castro, Rafael A.Lean Six Sigma has great impact in the removal of non-value-adding activities and improving business performance. It does so by applying tools and techniques to eliminate waste, and focus on implementing strategies to efficiently identify areas of opportunity and improve them. This research studies the effects of applying Lean and Six Sigma DMADV methodology for the improvement of an R&D service center functional process flow and performance. The methodology is applied to identify variability in the process flow, measure and analyze them with quality techniques and tools, and design remedies to improve turnaround time. The results provide key inputs to focus on for future studies relating to Lean Six Sigma execution. Key Terms ⎯ DMADV, Lean Six Sigma, Process Improvement, Service Center.