Aumento de la productividad en una línea de producción de adhesivos industriales

Abstract

CONDITION FOR PUBLICATION OF PROJECT. This project was developed in an industrial adhesives company facing a critical problem of low efficiency in one of its production lines. Despite having an installed capacity of 8,610 kg per week, the line only produced 2,124 kg, operating at just 12% of its potential. One of the main limitations was the natural cooling of the 6-ton mixer, which required between five and seven days per batch, creating a significant bottleneck. Additional issues included the restricted use of a single sealer, lack of planning for large orders, and the mixer being used as a storage container, all of which increased inefficiency. To address this, the DMAIC methodology was applied. In the define phase, objectives were established: increase productive capacity by at least 50% of the existing gap and ensure process sustainability. Measurement and analysis phases identified root causes and prioritized high-impact factors. Improvement initiatives included forced cooling, which reduced time from seven to 1.5 days, a “U” shaped layout redesign, implementation of a Master Production Schedule (MPS), and motor renewal. Finally, the control phase established monitoring mechanisms to sustain improvements. As a result, weekly production increased to 5,600 kg (+167%), with positive financial, environmental, and social impacts, transforming the line into a sustainable and competitive operation. Keywords: Continuous improvement, DMAIC, Industrial adhesives, Bottlenecks, Operational efficiency