การลดความสูญเสียในกระบวนการผลิตน้ำดื่มบรรจุขวด กรณีศึกษา โรงงานผลิตน้ำดื่ม

Abstract

The purpose of this research was to reduce the loss of materials in bottling water in manufacturing process by applying DMAIC, Six Sigma methodology. The study begins with study the generic issues and define the losses in the process. Majority of loss classified by cost are preform, water treated and closure, respectively. The measure phase can be defined that 4 machines that related with the issues and classified to 8 types of major losses. After brainstorming to find out the root cause by Cause & Effect Diagram, there are 11 solutions to improve the process and successfully solved. 1) Test and Fine tune the appropriate temperature for heating the preforms 2) Changes the spindle set 3) Modify and cleaning Cooling water head supply pipe 4) Optimized the filled level compromise to Thai regulations 5) Standardized filling control criteria 6) Establish working standard, communication the procedure to Stop and re-start process of Filler machine 7) Define the criteria for closure's quality 8) Adjust sensitivity of cap camera to minimized the fault rejection rate by maintain zero defect of product 9) Adjust positioning of Cap conveyor bar to avoid up side down closure 10) Setting leaking bottle detection to avoid losing to further step 11) Categorized the closure's defect and raise prevention from supplier. The finalized to control phase, prevent the repetitive issue. In conclusions, the study under control phase in 3 months showed the effectiveness of decreasing loss trend of materials in process, the loss ratio of Preform was reduce from 0.53% to 0.27% , loss ratio of Water Treated was reduce from 1.45% to 1.28% and loss ratio of Closure was reduce from 0.40% to 0.33%. This result show great impact to loss in process and result to minimized the production cost, where as product quality increasing. In addition, this study assist to obtain more effectiveness of work with standard and strong working system.