การลดของเสียในกระบวนการผลิต กรณีศึกษาในโรงงานถุงมือยางตัวอย่าง

Abstract

The objective of this research was to reduce the number of defect in gloves manufacturing process, targeting as no more than 1.5%, by applying principles of six sigma. Studying current and defining the problem indicated top three of defects as tear defect, incomplete bead defect and swell defect. Next, the measure phase was conducted by studying flow process of gloves production. It was showed that from 20 steps, only 11 steps were related with such problem. Brainstorming with the team contributed to find out root cause. These causes were assessed their severity and occurrence. The main causes of tear defect were excess lifetime of air regulator and no latex compound maturation time control from beginning of mixing until used up. The main causes of incomplete bead defect were excess lifetime of coil of drying oven 3 and lack of checking and maintenance of beading. Lastly, the main causes of swell defect were excess lifetime of coil of vulcanizing oven and no defined latex compound maturation time in case of urgent production. After analyzing each main cause, the following solutions were suggested. 1) Change air regulation, coil of drying oven 3 and coil of vulcanizing oven 2) Established machine check sheet of stripping machine, Beading machine and oven 3) Established operation standard of stripping machine, Beading machine and oven 4) Established latex compound maturation standard 5) Defined latex compound maturing time in case of urgent production minimum 16 hr which increase amount of catalyze by 20% of formulation. Consequently, after improving and controlling main causes for a period of 3 months, the defect was reduced from 1.698% to 1.463%. In other words, a sigma level was improved from 3.626 O up to 3.682 O