Aplicación de la metodología DMAIC enfocada en la mejora del proceso productivo en las líneas de retorcido y bobinado de hilos plásticos de la Empresa HIPLAS

Abstract

The aim of this work was to apply the Define, Measure, Analyze, Improve, and Control (DMAIC) methodology focused on the improvement of the production process in the twisting and winding lines of plastic yarns of the company HIPLAS. This methodology consists of five stages: define, measure, analyze, improve and control. Initially, it was resolver that Banana thread is one of the most required products in the agricultural market; however, customer acceptance of the company’s product is low. Through the application of surveys, it was determined that tensile strength, or breaking strength, was the critical to quality (CTQ) characteristic to be analyzed. On the one hand, tensile tests were carried out under the NTE INEN-ISO 2307 standard, which determined that the product was approximately 20% below the level of the competition. On the other hand, through the Failure Mode and Effects Analyze, it was found that the processes of melting the formula and the water cooling of the film are critical. Thus, an experimental design 22 was applied to determine its incidence on the CTQ, the same as when working at its high levels of 30ºC for cooling temperature and 350ºC for the melting temperature, showed its importance for the final product, as a result the optimum technical operating parameters. Due to the incapacity of the current process, support tools were designed for the staff which facilitated more efficient work, reflected in the increase of the Pp index from 0.62 to 1.02 and Pp from 0.49 to 0.87, as well as the reduction of approximately 47% in the standard deviation of the process. For the control of these processes, the acquisition of an AGGREKO chiller model WCC50 MK4 is recommended in response of the lack of a control system on the refrigeration process.