Abstract

The Increase Reliability: Improve OTC Boilers Cycle Capstone Project is designed to enhance operational efficiency in the Haleon’s Utilities Department by mitigating major deviations, particularly within the Utilities Area. The initiative primarily addresses challenges in the boiler room, responsible for 69% of the deviations. The existing boiler cycle falls below the required level, affecting chemical consumption, maintenance costs, and environmental sustainability. The project's aim is to identify factors impacting boiler house reliability and introduce improvements to optimize performance, boost boiler efficiency, reduce unplanned shutdowns, and ensure stable OTC production. Using industrial engineering knowledge, the project employs statistical tools, data analysis, and continuous improvement methodologies such as Six Sigma and the DMAIC approach. The Root Cause Analysis identified eleven (11) potential causes, grouped into four (4) categories:  Water Treatment, Boiler Cycle, Materials Availability, and Manpower. Three (3) implementation alternatives were identified for each category. The total cost of these alternatives is projected at $98,530.96, with anticipated annual savings of $74,404.96 and a cost avoidance per investigation of $6,490.00. With the alternatives implemented, the cycles increased from 3 to 15 by 214%. Now (YTD) no investigations related to the Utilities area have been reported, achieving 100% of the established objectives for the reduction of deviations.