Waste Reduction on Filler #4 in Vaqueria Tres Monjitas

Abstract

For this investigation, the DMAIC methodology was applied at the local company in Puerto Rico called Vaqueria Tres Monjitas. The purpose of this investigation is to identify a problem identified in milk production. It was then promptly identified that a waste of net product was present in the production utilizing DMAIC. It was then possible to further investigate this deficiency found. In the initial steps of the process a specific machine that is used in the production had to be chosen for the investigation and our sponsor advised us to investigate further into the production of whole milk for the “Federal 4” machine. Once this was determined different analysis were performed to ascertain this waste in the production, through a VOC (Voice of the Customer) it was possible to understand the business needs of the operators in the area for the DEFINE phase of the investigation. As for MEASURE, daily production data was provided for the months of January and February which detailed the production of each product for each machine. Through these different charts and graphs, we were generated to be able to visualize the data and reach conclusions from it more easily. Furthermore, through this exercise a percentage of waste of milk was identified and investigated further. Through these efforts, it was possible to determine up to a $1,347,225.66 in production loss in a year. With the different analysis and this investigation, an estimate of at least a 5% reduction in waste is expected, which totals up to a minimum of $67,361.28 in savings in a year.