Estudio de la metodología Lean Six Sigma en el proceso de inyección de suelas de la empresa Beltrán Inyecciones

Abstract

Mostly, the companies don´t have or don´t work with the Lean Manufacturing philosophy tools, at the same time, the companies don’t think about the possibility of implementing the Six Sigma methodology, as a result is that the organizations are affected by representative economic losses caused by waste and delays of times. For this reason, the purpose of this research is to develop a Lean Six Sigma study in the sole’s injection process of the company Beltrán Inyecciones. Because of the variability that exists in the productive processes of a company, in the present project, the DMAIC methodology (Define, Measure, Analyze, Improve, and Control) was used for the respective analysis of the processes, based on a qualitativequantitative approach, whereby, is carried out of data collection concerning the cycle times used for mold changes, main problem, essentially oriented in a non-probabilistic sampling for the meticulous study of the performance of the process through the help of the Excel and Minitab softwares. Lastly, an improvement proposal is prposed using the Single-Minute Exchange of Dies (SMED) system and the validation of the proposal is clarified through the simulation of the process in FlexSim 2019. The results obtained indicate that the drawback with the greatest impact falls on the delays in executing mold changes, generally it´s caused by the lack of organization on the mold shelves and by not having manuals of procedures, therefore, the data reflects low Sigma levels with an average value of 3.39, thereby, the process is not adequate as it does not meet established specifications. Finally, it is defined, with the help of the implementation of the Preparation Time Reduction system, of 39.38% reduction in the time required to change molds is achieved, which generates an estimated annual benefit of $17,328.00 dollars.