Ingeniería en Sistemas, Electrónica e Industrial

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Metodología Six Sigma para la reducción de desperdicios y residuos en el proceso de envasado en la empresa Pura Crema
(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas Electrónica e Industrial. Carrera de Ingeniería Industrial., 2026-01)
Silva Torres, Sebastián Euclides
;
Morales Perrazo, Luis Alberto
;
Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas Electrónica e Industrial. Carrera de Ingeniería Industrial.
Waste in packaging processes within the food industry generates inefficiencies and economic losses, mainly due to filling variations, packaging failures, equipment instability, and operational errors. These factors increase waste and affect product quality; therefore, this study aimed to reduce the waste generated in the yogurt packaging process at the company Pura Crema, located in the San Pedro de Pelileo canton, Tungurahua province. A quantitative methodology was applied through the implementation of the DMAIC cycle within a Six Sigma project, supported by tools such as ABC analysis, statistical control charts, Failure Mode and Effects Analysis (FMEA), cause-and-effect diagrams, and the 5W and 2H technique. This approach made it possible to prioritize defects and accurately assess the capability of the yogurt packaging process. The results revealed that the critical CTQs are the filling level and bottle deformation in the packaging process. Although the process is stable, its inability to ensure uniform filling and properly formed containers increases the number of defects. The root cause analysis showed that these deviations stem from a lack of process standardization, personnel distraction, and instability in temperature control during the blowing stage, thereby limiting the process capability to remain within the established quality parameters. Finally, it is concluded that the process presents a Sigma Level of 0.67 for the overflow defect, equivalent to 250,000 PPM, which implies significant economic losses. Therefore, the main opportunity for improvement lies in the implementation of standardized protocols and operational controls that allow progress toward a competitive Sigma level and mitigate process variability.
Análisis estadístico de la calidad en los procesos de inyección de plástico de la empresa Ecuatoriana de Matricería Ecuamatriz Cía. Ltda.
(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial, 2024-08)
Pazmiño Lizano, Miguel Ricardo
;
Morales Perrazo, Luis Alberto
The suboptimal quality control in the plastic injection process engenders a 3% loss due to defects such as incomplete, marbled, and deformed parts at ECUAMATRIZ Cía. Ltda. This directly translates into diminished product reliability and potentially dissatisfied clientele. To address this impact, a statistical analysis of quality in this process was developed. A quantitative and descriptive approach based on Six Sigma and DMAIC (Define, Measure, Analyze, Improve, and Control) was employed. For definition, data was collected through records and Pareto diagrams. For measurement, 100% sampling, R&R studies, and control charts were utilized. The analysis identified root causes using Ishikawa diagrams and the 5 Whys method. For improvement and control, the FMEA matrix was implemented, determining the most significant root cause and developing proposals with experienced personnel. The analysis of P control charts for attributes revealed unstable processes for marbling (5.5%), incomplete parts (0%), and deformation (2.7%), with sigma levels of 1.99, 2.06, and 2.64 respectively, evidencing deficient statistical control and high variability. The root causes were identified as lack of preventive maintenance, absence of records and control of critical parameters (temperature, pressure, injection speed, among others), lack of cleaning procedures, and insufficient personnel training. It was concluded that the plastic injection process exhibits a low level of quality and control, operating below globally required standards, representing an annual loss of 1.98% in terms of defects, reprocessing, and waste.
Variabilidad estadística en la producción del cuero de la empresa Curtiembre Quisapincha
(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial, 2024-08)
Chuquiana Tamaquiza, Edison Israel
;
Morales Perrazo, Luis Alberto
The scarce quality control in the tanning industry represents a problem for small and medium-sized companies. In this sense, the research focused on determining the statistical variability present in the leather production processes in the company CURTIEMBRE QUISAPINCHA. The study was carried out using the Six Sigma and DMAIC (Define, Measure, Analyze, Improve and Control) methodologies. In the define phase, data collection techniques such as observation sheets and Pareto diagrams were used. In the measure phase, process variability was determined by using tools such as R&R tests, control charts and capability indices. The analysis was determined by means of the 5-whys and Ishikawa diagrams and finally, in the improvement stage, the 5W-2H tool and the 6 quality m's were used to establish a quality control proposal. The results obtained showed that the defects of "tears or breakage", "different thickness", "scratches" and "holes", are the main problems that cause variability in production, due to causes such as lack of technological innovation, little or inefficient training in the use of machinery or work methods, personnel turnover, for this same reason the sigma level of the company is 2.53, being this value below the desired sigma level (6σ) for the leather industrial sector. It is concluded that the company with the sigma levels mentioned above generates an average of 155,000 defects per million produced, which we are seeking to reduce to 3.4 defects per million opportunities and place the company as world class.
Análisis de la variabilidad en los procesos productivos en la empresa de calzado Pool Sport mediante la metodología Six Sigma
(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial, 2024-08)
Montenegro Rodríguez, Bryan Santiago
;
López Flores, Mauricio Xavier
The research project focuses on analyzing the variability present in the production processes at POOL SPORT, with the objective of proposing an action program to reduce defects using Six Sigma tools and methodologies. These are presented in a list designed to identify the main improvement alternatives, aimed at addressing critical issues, thereby reducing defects in the operational area, decreasing variability, improving the quality of the final product, and increasing customer satisfaction. Through bibliographic-documentary research, field research, and applied research, all the information and data were collected, including the historical sales data for the period (July - December 2023). An ABC analysis was performed, allowing the identification of the most profitable product. Based on this model, information was gathered, followed by the creation of process diagrams to understand the current situation of the company and the current working method employed at the facilities. Tools such as interviews and Pareto diagrams were used to identify defects in the operational area, such as: unstitched pieces 26%, adhesive stains 20.9%, pieces with cutting defects 13.2%, poorly stitched labels 12.4%, irregular cuts 10.9%, loose seams 5.8%, incorrect soles 5.8%, and defective stamping 5.0%. These defects were associated with factors related to labor and raw materials identified through cause-and-effect analysis and the FMEA matrix. Once the critical processes (stitching and sole attachment) and potential defects (adhesive stains and unstitched pieces) were identified, with quality levels for the processes at 2.46σ and 2.70σ respectively, as well as Yield efficiencies of 83.1% and 88.5% respectively, the negative situation of the processes was exposed. Finally, improvement proposals based on the DMAI analysis were developed, where alternatives were established that should be maintained over time through the records and programs outlined in the Control (C) stage.
La calidad fitosanitaria en las flores de exportación de la empresa Sisa Green Flowers
(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial, 2024-08)
Changoluisa Calapaqui, Francis Alfonso
;
Morales Perrazo, Luis Alberto
Phytosanitary quality control in export products is fundamental to ensure customer satisfaction and product quality, therefore, this research focused on evaluating the performance of quality control during lot inspection at SISA GREEN FLOWERS. The research applied the DMAIC (Define, Measure, Analyze, Improve and Control) methodology with a quantitative approach to address the quality problem. The problem was defined using Pareto diagrams, brainstorming and flow charts. Measurement developed systematic sampling to generate 135 subgroups to develop control charts of critical variables. The analysis used Ishikawa diagrams and 5W technique. Finally, the proposed improvement seeks to solve the root cause of defective product acceptance. Quality defects were analyzed using critical quality variables (CTQ's). Consequently, the results of the study show that the defect "presence of mites" presents problems with the variable "compliance with phytosanitary protocols for mites" because it showed a level of 0.6291 sigma. The defect "affections by thrips" was evaluated integrally, obtaining 0.7067 sigma. As for defects related to "stem deterioration", the variable "stem appearance" was identified as having a level of 0.7204 sigma. All variables generate out-of-specification products. Finally, the quality level turns out to be very low, affecting the company's reputation and generating possible significant financial losses, estimated at around $4137,13 for each shipment of products to customers abroad.
Control de calidad en los procesos de confección de ropa interior de la corporación Impactex Cía. Ltda.
(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial, 2024-02)
Manobanda Chuquicondor, Ángel Darío
;
Morales Perrazo, Luis Alberto
El bajo control de calidad en la confección de ropa interior genera grandes pérdidas económicas para las empresas de esta rama productiva, por lo cual, la investigación se centró en evaluar el desempeño de control de calidad en los procesos de confección de ropa interior de la Corporación Impactex Cía. Ltda. El estudio utilizó una investigación descriptiva y un enfoque cuantitativo basado en la metodología Six Sigma y su herramienta DMAIC (Definir, Medir, Analizar, Mejorar y Controlar). En la fase de definir, se empleó técnicas como lluvia de ideas, 5W-2H y diagrama de Pareto. La etapa de medir implementó un muestreo sistemático del 100% de los productos en un periodo de 15 días. El análisis se realizó mediante el diagrama de Ishikawa, los 5 por qué y el AMEF. Y finalmente, en la fase de mejora se utilizó la herramienta 5W-1H para la propuesta de control. Los resultados arrojan que los defectos de "fallas de costura" y "manchas de aceite" son los principales responsables de ocasionar variabilidad en la producción (49,7% y 25,2%, respectivamente). Esto se atribuyó a la falta de capacitación en técnicas de costura, rotación frecuente del personal, carencia de mantenimiento preventivo en las máquinas de coser y ausencia de protocolos de limpieza. Además, el análisis Six Sigma reveló que el proceso está fuera de control estadístico, con 36151 PPM fuera de especificaciones y un nivel sigma de 1,8 para fallas de costura, y 5837 PPM fuera de especificaciones con un nivel sigma de 2,52 para manchas de aceite. Se concluye que el proceso de confección de ropa interior presenta un bajo control estadístico de calidad en su confección, debido a que el nivel sigma actual de la empresa está por debajo de lo recomendado para la industria textil que deberían estar de 3 a 4 sigmas.
Metodología Dmaic Six Sigma para el control de la calidad del calzado de seguridad en la empresa Calzado Sinell
(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial, 2023-09)
Condo Llerena, Jefferson Ariel
;
Morales Perrazo, Luis Alberto
The footwear industry suffered a severe impact in recent years as an effect of the confinement due to the 2020 pandemic, causing an 80% reduction in footwear production with respect to the previous year, leading to the closure of several companies or mass layoffs, especially for small and medium enterprises. Due to this situation, it was decided to control the quality of safety footwear by applying the DMAIC Six Sigma methodology at Calzado SINELL, aiming to improve production quality and maintain competitiveness in the market. The methodology used in the project was descriptive and field, applying the 4 phases of the DMAIC Six Sigma methodology (Define, Measure, Analyze, Improve) to the highest-demand product of the company Calzado Sinell over a period of 5 weeks of analyzed production. The main quality problem occurs in the sole attachment process and is the "excess or shortage of glue," representing 40% of all defects found. The Six Sigma analysis reveals that the process is currently unstable and out of statistical control, resulting in approximately 66 807 units are produced outside their specifications for every million produced, with a yield of 93,82% and a sigma level of 3,04. It concludes that the company does not perform adequate quality control on its product, leading to excessive process variability. This problem is caused by the lack of technical specifications and standardized processes.
Análisis Six Sigma en el proceso de montaje de la empresa calzado GAMOS
(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial en Procesos de Automatización, 2023-03)
Gavilanez Gavilanez, Juan Carlos
;
Morales Perrazo, Luis Alberto
The footwear assembly process is the most important operation in the manufacture of shoes, since its objective is to assemble the cut on the last and the insole, put counters and assemble tips, sides and heels; however, it is a potential source of defects and problems that cause a high variability in the production method; therefore, the present research aims to perform a six sigma analysis in the assembly process of the company GAMOS Footwear. The research has a quali-quantitative approach, which is based on the use of the DMAIC (Define, Measure, Analyze, Improve and Control) methodology; to carry out the study, the data are collected in a period of approximately one month, through a systematic random sampling of 20 production orders received, in the footwear model with the highest demand. The results obtained show that the defect of "unstuck edges" is the most responsible for production errors (53%), which is mainly due to the presence of attributable causes such as: carding dust in the air, poorly carded sides, loose or poorly glued sides to the last, continuous rotation of operators, too much workload and poor assembly of the shoe upper. The six sigma analysis determines that the process is out of statistical control, as it has 4237 PPM out of specification, which indicates a process yield of 93% denoting a sigma level of 2.96 sigmas. It is concluded that the assembly process of the company under study presents a low statistical control in the production of its products, since it presents a sigma level below the average of the footwear companies (3 to 4 sigmas).
Análisis de defectos en el proceso de confección de bividis en la empresa M&B Textiles bajo la metodología Six Sigma
(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial en Procesos de Automatización, 2022-09)
Guerrero Merino, Jorge Patricio
;
Ortiz Sailema, Christian Ismael
The poor quality of textile products had a negative impact on companies, which caused economic losses by selling second-hand garments at a lower price, for which the present investigation aims to develop an analysis of defects in the process of making garments. bividis in the company M&B Textiles under the Six Sigma methodology. The methodology used is developed based on the six sigma steps such as Define, measure, analyze, improve and control, in order to determine potential failures and establish proposals for improvement. The results of the defects underlie in the manufacturing area with defects of higher concentration in oil stains with 60.63% and unpolished seams with 18.90%, in which they represent sigma values of 2.37 and 3.02 that indicate that the process has a low performance that modifications must be made in the process. It is concluded that the main causes of the second-hand products are related to the lack of maintenance of sewing machines, lack of cleanliness and the lack of a correct identification protocol for garments, for which, through the improvement proposal, the procedures are established. and instructions to be applied and improve the quality of the product.
Estudio de la metodología Lean Six Sigma en el proceso de inyección de suelas de la empresa Beltrán Inyecciones
(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial en Procesos de Automatización, 2022-09)
Quisintuña Toalombo, Angel Klever
;
Lema Chicaiza, Freddy Roberto
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.

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