Scrap Reduction Evaluation of Filling Equipment and Short-Term Improvement Implementation

Abstract

This paper seeks to document an approach to reduce scrap losses using the Lean Six Sigma tools for process improvement in a lean manufacturing environment. The Lean Six Sigma methodology views lean manufacturing, which addresses waste issues, and Six Sigma, with its focus on design, as complementary disciplines aimed at promoting "business and operational excellence”. DMAIC (Define, Measure, Analyzed, Improved, and Control) is used for projects aimed at improving an existing business process. Assessments of the manufacturing processes and interviews with key personnel to determine potential opportunities were performed by means of Voice of the Costumer. The project starts with the definition and measure phases, followed by the analysis phase and ends with improve and control phases. Supporting data are presented using Pareto charts to prioritize waste in order to be more focused for improvement. DMAIC methodology was employed to identify the areas in which the product is discarded (waste). Evaluation revealed that the product that remains in the silastic hose and not transferred in the carboy is the major contributor of the product loss at the filling stage. Scrap reduction into filling equipment was successfully employed to improve manufacturing productivity. Twenty five percent (25%) of cost improvement were the immediate benefits attained from implemented process improvements. Key Terms - DMAIC methodology, Lean Six Sigma, Voice of the Costumer (VOC), Waste.