Reduction of 15% in Spare Parts Consumption Costs in Automated Non-Absorbable Suture Automated Process

Abstract

This project evaluates spare parts consumption behavior within automated non-absorbable suture Swaging and Winding operations, with the objective of understanding the drivers of cost escalation, variability, and maintenance-related usage. The project scope is limited to physical spare parts consumption associated with preventive and corrective maintenance activities, excluding procurement strategies, pricing effects, and changes in production throughput. The Lean Six Sigma DMAIC methodology is applied to structure the investigation. The Define, Measure, and Analyze phases identify systemic drivers of overconsumption, highlighting gaps in preventive maintenance execution and opportunities for SOP optimization through clearer replacement criteria and standardized decision-making. The Improve phase focuses on mitigation strategies centered on standardization and technical alignment, while the Control phase introduces a business oriented control proposal designed to sustain improvements through governance, accountability, and continuous improvement rather than relying solely on procedural enforcement. Overall, the project establishes a repeatable, data driven framework for controlling spare parts consumption while maintaining equipment reliability and operational stability.