Improvement of chocolate packaging line

Abstract

The Improvement of the Chocolate Packaging Line Project at Novartis Ex-Lax Inc. in Humacao, Puerto Rico, aims to enhance the Overall Equipment Effectiveness (OEE) of its packaging line to 60% by the end of 2014. The project identifies critical drivers of improvement through a CTQ Tree and a SIPOC Diagram, focusing on minimizing downtime, speed losses, and defect losses. High-level process mapping revealed the stages of chocolate packaging, with Process Operation Diagrams developed for three setups (A, B, and C), detailing operations and inspections. A data collection plan uncovered inaccuracies in OEE calculation, limited to performance measures, neglecting availability and quality. Incorporating these elements revealed an average OEE of 39.58% from October 2013 to February 2014. Key downtime causes, identified using Pareto Charts, included schedule downtimes, changeovers, minor stoppages, and speed losses. Waste analysis highlighted waiting, reprocessing, and over-processing issues, while root-cause analysis via Fishbone Diagrams pointed to material delays, machine downtimes, and measurement errors. The project proposes installing a reliable data system to monitor and display real-time metrics such as running time, output, and scrap, facilitating accurate OEE calculations. This system could generate annual savings of over $14,000. Additionally, implementing a zero-quality control system is recommended to detect nonstandard conditions preemptively, potentially saving $53,000 annually. Further recommendations include ongoing preventive maintenance and autonomous maintenance to prevent losses. The implementation strategy involves revising SOPs, pilot testing, and monitoring before formalizing a control plan that aligns with quality standards and customer expectations. These measures are expected to standardize operations and ensure sustainable improvements, achieving the project’s OEE enhancement goal.