Optimización del proceso de llenado y dosificado de preenvasados en relación a su utilidad financiera basado en six sigma: caso de estudio Solinag Cia. Ltda

Abstract

By reducing costs as well decreasing waste, variability and dead times, optimization helps organizations to manage better their economic resources while improving the quality of their products and services. As result, long term benefits and client satisfaction are achieved. The aim of this study is to present the results obtained from optimizing the filling and dosing processes of four prepacked batches 100 ml, 250 ml, 500 ml and 1000 ml of agricultural liquid. A statistical control and capacity analysis, has been made to determine the variability; due to product excess or waste, in the current and in a new optimal state of the process. The guidelines established in the Ecuadorian Technical Regulation INEN 284 were followed in the study as well as process optimization methodologies, such as Six Sigma. The latter one was applied through DMAIC, which consisted in five fundamental steps (Define, Measure, Analyze, Improve and Control) and Design of Experiments, through a 2 3 factorial design included a study of the main factors that intervened directly in the process. The study was carried out creating ideal conditions and it was found that there are three crucial influencing factors: a) The air pressure that is exerted in the tank or bin where the product is located, b) the air pressure of the filling piston and c) the level of the flow of the filling system. A new control plan with new tolerances by having previously calculated new upper and lower specification limits was recommended. In this way, the losses of the company were rebounded from approximately $ 4.448,48 to $385, 95 per year