Metodología Six Sigma para la reducción de desperdicios y residuos en el proceso de envasado en la empresa Pura Crema

Abstract

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.