Lead Time Reduction of CapSure Assembly Process and Material Flow Design Improvement

Abstract

This capstone project was developed at Becton, Dickinson and Company (BD) Humacao, Puerto Rico, focusing on the CapSure Permanent Fixation System assembly line. The project was conducted using the DMAIC (Define, Measure, Analyze, Improve, Control) methodology with the objective of reducing the excessive manufacturing lead time of approximately three days and improving the line’s ability to consistently meet the required daily demand of 610 units. The analysis identified that multiple sub-assemblies were being produced separately through batch processing, creating interruptions in material flow, excessive work-in-process (WIP), transportation waste, operator waiting time, and bottlenecks across the production system.