Track: Lean Six Sigma Competition

Abstract

To increase the output of a production line, it is necessary to identify the main causes of stoppages and establish measures to avoid them. This research describes the development of a Lean Six Sigma (LSS) project in a Chilean company that produces berry-based products. The aim is to increase output on dried fruit (DF) production line. A methodology based on the DMAIC cycle, and the application of principles and methodologies Lean was used. The output increase problem was divided into two sub-problems: unexpected stops and waste, based on the overall equipment efficiency (OEE) concept. The solutions focused on the cutting and selection, which are intended to maintain a stable flow of fruit throughout the process and avoid defects within the production line. The production solutions included mandatory temperature controls of the fruit to be processed, changes in the interior design of machines, application of visual management for cleaning, and action protocols. According to the results of the case study, a 42% decrease in the time lost due to breakdowns and a 50% reduction in the waste generated were obtained. In general, an increase in the output of the DF product of 9.3% is estimated.