Implementação de um projeto de melhorias em um processo de reação química em batelada utilizando o método DMAIC

Esta dissertação apresenta a implementação das etapas do método DMAIC (Definir, Medir, Analisar, Melhorar e Controlar) no desenvolvimento de um projeto Seis Sigma em uma indústria petroquímica. O objetivo do projeto Seis Sigma foi reduzir a variabilidade de uma característica de qualidade crítica para o cliente e diminuir a dispersão dos tempos de reação entre as bateladas na produção de elastômeros. Neste trabalho são apresentadas as principais técnicas e ferramentas estatísticas utilizadas nas cinco etapas do método DMAIC, tais como brainstorming, mapeamento de processo, diagrama de causa e efeito, matriz da causa e efeito, gráfico de Pareto, FMEA e análise de regressão linear múltipla. A pesquisa desenvolvida de forma participativa, através da interação entre o pesquisador e os especialistas do processo, evidenciou a importância do conhecimento técnico do processo e um bom planejamento para a aquisição dos dados, como pontos importantes para a realização de um projeto de melhoria bem sucedido. O estudo apontou ainda, deficiências no sistema de controle de temperatura do reator, no sistema de medição para a característica de qualidade viscosidade Mooney e no sistema de dosagem dos insumos.

Uma aplicação do planejamento de experimentos e carta de controle em uma indústria de cosmésticos: ciclo DMAIC

Pós-graduação em Engenharia de Produção - FEB

Aplicação do DMAIC em uma indústria farmacêutica

In an industry, being a big one or small one, the process improvement is always a focus for it to increase in the market. The improvement, if searched in a simple meaning, brings the unique meaning of change to better. However the meaning of process improvement can take much more than a superficial point of view. Kaizen, Process improvement, Continuous improvement, they are some denotations much more comprehensive of a such a term carried of so many meanings. A good concept of improvement if to search inside processes a more appropriate way, a more succinct, a more economic way to realize it. The idea is to make the process in a better way. In this graduation thesis, there will be presented a process improvement realized in a Vale do Paraíba company. For that, it was used the DMAIC to obtain, measure and control the process improvement. It should be noted that the goal is to present and discuss a process improvement

Identificação de causas especiais no processo que aumentam a ocorrência de poro na solda de tubos de aço: aplicação etapas definir, medir e analisar do DMAIC

This work covers the methodology Six Sigma with the application of the steps Define, Measure and Analyze a company of steel tubes, with the objective of identify special causes in the process that drives the creation of the pore defect in the solder. It is highlighted the fact that this work is the base of an continuous upgrade project that aims in eliminating the occurrence of this defect. The motivation is given to the necessity of improving the productivity of the factory, considering that the defect occurs at random and your causes are unknown. This way, it was defined that the problem to analyze, measured the capability of the process in DPMO and analyzed with the aid of graph by attribute P. The results show the process that present special cases, as well as the process considered ideal, This way it was stated that in this work, the processes destabilized and the controlled, allowing a comparison of the characteristics for the elaboration of concise action plans to eliminate the defect. The project must follow the steps Upgrade and control the methodology Six Sigma, in order to ensure success in his execution, aiming to amplify the competitive edge of the business

Estudo de caso: aplicação do método DMAIC-White Belt- na redução de latas amassadas em uma produção de leite em pó

This work consists of the implementation of the steps Define, Measure , Analyze , Improve and Control ( DMAIC ) to develop a Six Sigma project in an industry the food industry. The objective was to demonstrate a potential for reducing the occurrence of crushed cans in potting milk powder industry in a White Belt project. The food industry accounts for about 9 % of Brazil's gross domestic product ( GDP ), generating thousands of jobs . Among the major sectors of the food industry is the manufacturing sector of milk , occupies approximately 10 % of the total turnover of the food industry . Brazil is considered today one of the eight largest producers of milk powder in the world. The milk powder is packed , mostly for aluminum cans that are lined internally with varnishes and other materials to protect the milk of metals from aluminum. When the cans are dented food protection is compromised and may lead ingestion causing dis-eases such as botulism. Aiming to solve the problem of dented cans methodology was used as a case study with a quantitative approach through the DMAIC method. Some quality tools used in each step of the project as brainstorming , cause and effect diagram , flowchart , ef-fort and impact matrix, 5W1H , among other Pareto diagram is presented . A survey about the disposal of cans in the company verifying a mean loss and, from this histor-ical , a goal loss was calculated was performed . With the target set we calculated the annual saving design . During application of DMAIC was found that the highest rate of loss occurred in transportation between the factory and the factory that fills cans milk . Several actions were taken to resolve problems that resulted in dented cans and the first two months of phase control it was found that the smaller losses calculated target resulting in a saving for the company. The short time of implementa-tion of the Improve phase did not allow a more detailed a ...

Projeto DMAIC com ferramentas six sigma para redução de custos logísticos de uma multinacional

This work has a focus on project execution DMAIC ( Define Measure Analyze Implement Control) , using the statistical and quality tools to identify , analyze and implement improvements in a given process in order to reduce costs telephony transport of a multinational consumer goods . The multinational consumer goods to be studied has outsourced carriers who perform the distribution of its products , which may lead them straight to their factories or one of its distribution centers to the points of sale ( supermarkets , bakeries , gas stations , convenience cafeterias , among others ) . Whenever there is an unexpected situation or some problem at the time of delivery of the goods to the customer opens an occurrence , ie , the carrier responsible for contacts ( 0800 ) with the contact center company of consumer goods which in turn registers the occurrence, analyzes and sends a response action to the carrier . This work will study the problem with a high number of connections to handle occurrence , through analysis and data collection , identify improvement opportunities, implement them and monitor the results to ensure that the gain and loss reduction are sustainable

Projeto DMAIC com ferramentas Seis Sigma para redução de sucata em uma multinacional do ramo de acessórios automobilísticos

In this era of globalization, with fierce competition in the labor market, using the reduction cost strategy and resources optimization, has become a competitive advantage. In this graduation study, it will be exposed in form of case study the DMAIC project (Define Measure Analyze Improve Control) execution, using of Six Sigma's tools, statistical and quality knowledge, with intent of analyze, improve and control the processes of a selected problem, always demonstrating good practice of methodologies. In an auto parts multinational branch, It was identified a high scrap rate in one of his production lines. This work will study this problem to improve their processes and ensure that these improvements are perpetual. As a result, reached the stipulated goals, increasing Corporation's Intellectual, thereby providing a competitive advantage

Melhoria de eficiência de máquinas pela metodologia DMAIC em eventos Kaizen

In a highly competitive and globally integrated market, excellence in production processes has become a survival factor, instead of just a differential point. In this context, companies from various sectors have resorted to philosophies and techniques already established in the literature to improve the efficiency of their production processes. This paper discusses aspects and techniques used to improve the production efficiency of a multinational company that manufactures surgical devices to a global market. Through DMAIC methodology, there were found opportunities to improve machines' efficiency by OEE, an efficiency indicator, in Kaizen Events. A case study was conducted to analyze the methodology and to identify good practices and difficulties along the way

Melhoria de eficiência de máquinas pela metodologia DMAIC em eventos Kaizen

In a highly competitive and globally integrated market, excellence in production processes has become a survival factor, instead of just a differential point. In this context, companies from various sectors have resorted to philosophies and techniques already established in the literature to improve the efficiency of their production processes. This paper discusses aspects and techniques used to improve the production efficiency of a multinational company that manufactures surgical devices to a global market. Through DMAIC methodology, there were found opportunities to improve machines' efficiency by OEE, an efficiency indicator, in Kaizen Events. A case study was conducted to analyze the methodology and to identify good practices and difficulties along the way

Aplicação da metodologia DMAIC a uma linha de produção de cartão canelado

O presente trabalho resultou da realização de um estágio curricular na empresa Fábrica de Papel e Cartão da Zarrinha, S.A.. O trabalho incide sobre a aplicação da metodologia DMAIC da abordagem Seis-Sigma a uma linha de produção de cartão canelado, mais especificamente a um tipo de não conformidade do mesmo, denominado por cartão com Warp (ou cartão com empeno). Através desta aplicação, foi possível encontrar as principais causas-raíz do problema em questão e delinear possíveis ações de melhoria para solucionar o mesmo. Durante a implementação desta metodologia foram utilizadas várias ferramentas de qualidade que permitiram uma melhor gestão e tratamento da informação de forma a agilizar alguns processos também como a comunicação interna. Sob a forma de resultados, além de se testemunhar a diminuição de placas e embalagens de cartão com warp, conseguiu-se também a sensibilização dos vários departamentos para a problemática em questão e, principalmente, para a utilização e consciencialização da metodologia Seis-Sigma e dos seus benefícios.

Comparative study of DFSS in product and service innovation

Six sigma has proven itself as a major quality initiative in the last two decades. It is a philosophy which provides a systematic approach to applying numerous tools in the framework of several quality improvement methodologies. The most widely used six sigma methodology is DMAIC, which is best suited for improving existing processes. In order to build quality into the product or service, a proactive approach like Design for Six Sigma (DFSS) is required. This paper provides an overview of DFSS, product innovation, and service innovation. The emphasis is on comparing how DFSS is applied differently in product and service innovation. This paper contributes by analysing the existing literature on DFSS in product and service innovation. The major findings are that the DFSS approach in services and products can be differentiated along the following three dimensions: methodology, characteristics, and technology.

Achieving quality improvement in the mask manufacturing industry by using Six Sigma technique

The Six Sigma technique is one of the quality management strategies and is utilised for improving the quality and productivity in the manufacturing process. It is inspired by the two major project methodologies of Deming’s "Plan – Do – Check – Act (PDCA)" Cycle which consists of DMAIC and DMADV. Those two methodologies are comprised of five phases. The DMAIC project methodology will be comprehensively used in this research. In brief, DMAIC is utilised for improving the existing manufacturing process and it involves the phases Define, Measure, Analyse, Improve, and Control. Mask industry has become a significant industry in today’s society since the outbreak of some serious diseases such as the Severe Acute Respiratory Syndrome (SARS), bird flu, influenza, swine flu and hay fever. Protecting the respiratory system, then, has become the fundamental requirement for preventing respiratory deceases. Mask is the most appropriate and protective product inasmuch as it is effective in protecting the respiratory tract and resisting the virus infection through air. In order to satisfy various customers’ requirements, thousands of mask products are designed in the market. Moreover, masks are also widely used in industries including medical industries, semi-conductor industries, food industries, traditional manufacturing, and metal industries. Notwithstanding the quality of masks have become the prioritisations since they are used to prevent dangerous diseases and safeguard people, the quality improvement technique are of very high significance in mask industry. The purpose of this research project is firstly to investigate the current quality control practices in a mask industry, then, to explore the feasibility of using Six Sigma technique in that industry, and finally, to implement the Six Sigma technique in the case company to develop and evaluate the product quality process. This research mainly investigates the quality problems of musk industry and effectiveness of six sigma technique in musk industry with the United Excel Enterprise Corporation (UEE) Company as a case company. The DMAIC project methodology in the Six Sigma technique is adopted and developed in this research. This research makes significant contribution to knowledge. The main results contribute to the discovering the root causes of quality problems in a mask industry. Secondly, the company was able to increase not only acceptance rate but quality level by utilising the Six Sigma technique. Hence, utilising the Six Sigma technique could increase the production capacity of the company. Third, the Six Sigma technique is necessary to be extensively modified to improve the quality control in the mask industry. The impact of the Six Sigma technique on the overall performance in the business organisation should be further explored in future research.

Reducing bubble defect on the outsole production process in the footwear manufacturing industry

The purpose of this study is to discover the significant factors causing the bubble defect on the outsoles manufactured by the Case Company. The bubble defect occurs approximately 1.5 per cent of the time or in 36 pairs per day. To understand this problem, experimental studies are undertaken to identify various factors such as injector temperature, mould temperature; that affects the production of waste. The work presented in this paper comprises a review of the relevant literature on the Six Sigma DMAIC improvement process, quality control tools, and the design of the experiments. After the experimentation following the Six Sigma process, the results showed that the defect occurred in approximately 0.5 per cent of the products or in 12 pairs per day; this decreased the production cost from 6,120 AUD per month to 2,040 AUD per month. This research aimed to reduce the amount of waste in men’s flat outsoles. Hence, the outcome of research presented in this paper should be used as a guide for applying the appropriate process for each type of outsole.

6Sigma在系统集成过程中的应用

6Sigma是实现过程控制和持续改进的有效方法,本文针对复杂系统集成过程管理存在的问题,分析了6Sigma在系统集成过程管理中应用的可行性,提出了一种基于6Sigma的系统集成过程模型.该模型具有信息及时反馈、过程持续改进、提高质量和降低成本的特点,在项目中得到应用并取得明显效果.

Process Improvement in Phlebotomy

This study has two main objectives. First, the phlebotomy process at the St. Catharines Site of the Niagara Health System is investigated, which starts when an order for a blood test is placed, and ends when the specimen arrives at the lab. The performance measurement is the flow time of the process, which reflects concerns and interests of both the hospital and the patients. Three popular operational methodologies are applied to reduce the flow time and improve the process: DMAIC from Six Sigma, lean principles and simulation modeling. Potential suggestions are provided for the St. Catharines Site, which could result in an average of seven minutes reduction in the flow time. The second objective addresses the fact that these three methodologies have not been combined before in a process improvement effort. A structured framework combining them is developed to benefit future study of phlebotomy and other hospital processes.