Electrospinning Process Capacity Optimization In Medical Device Industries

Abstract

As part of the manufacturing cost reduction initiatives that support 2021 Operational Excellence Projects to promote continuous improvement on medical device industries; the Electrospinning (E-spin) process was found with capacity opportunities associated to inconsistency and high nozzle pass counts to construct a single corepin unit. With the intent to improve the E-spin corepin daily outputs by a 50%, the solution provided was to convert machine from single-needle to double-needle by maximizing machine free space and activating the secondary tecothate supply pump. E-spin capacity problematic was studied and analyzed through DMAIC methodologies based on Lean Six Sigma to identify all possible solutions. Hence, the E-spin process was not only improved by a 50% the corepin daily output; the machine time was reduced by a 30% finding consistency and reducing nozzle pass count. The implementations of these solutions reduced the E-spin weekend extended shift, providing a total of $124,530.11 in saving to the company. Key Terms ⎯ Corepins, DMAIC, Electrospinning, Multi-needle