Análisis Six Sigma en el proceso de montaje de la empresa calzado GAMOS

Abstract

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).