Reducción de desperdicio en proceso de impresión de láminas de hojalata

Abstract

This project focused on reducing waste generated in the printing line through the application of the DMAIC methodology, which is structured into five phases: Define, Measure, Analyze, Improve, and Control. The main problem identified was the high percentage of sheets with dents, which contributed an average of 1.86% to total process waste between February and September 2025, representing 47.85% of the total waste on the printing line. Based on process analysis, actions were established to improve operational efficiency, reduce waste-related costs, and strengthen operator involvement, revealing deficiencies in operational control. In addition, the main root causes were identified, including sheet misalignment, damaged pallets, inadequate equipment cleaning, and the lack of standardization in operational and maintenance activities. As part of the process of improvement actions, low-cost solutions were implemented, such as visual pallet labeling, standardized cleaning kits for each production line, and preventive alerts. As a result, the average waste percentage decreased from 3.91% to 3.39%, demonstrating a sustained improvement in process performance and providing a solid foundation for future process optimizations. Keywords: DMAIC, waste reduction, industrial printing, process improvement.