Continuous improvement in a repellent filling line: Case study

Abstract

Currently, we live in a scenario where the repellent market is increasingly competitive due to the high demand, not only in seasonal seasons, but also due to the prevention of diseases transmitted by mosquitoes. In this context, companies seek to maintain customer loyalty and reduce production costs, so that they can offer more affordable prices. One of the biggest offenders that affect the cost of the final product is production waste, such as overfill, so that there is no such loss, processes need to be capable and have a certain degree of reliability. This study aims to decrease the variability in the process of filling a repellent line, which has a Cpk of 0.65, for a Cpk equal to or greater than 1.33, using the DMAIC methodology, from the Six Sigma program. In the development of each stage of the project, we sought to understand the critical variables in the filling, so that with the statistical justification of each one, the process could be optimized. As a result of the implementation of the methodology, a methodology was obtained for statistical control of the line on a daily basis, in addition to a greater engagement of the operational team with the control process, as well as an average Cpk of 1.48 during a quarter.