Reducción de los paros no programados en el área litográfica de una fábrica de envases

Abstract

CONDITION FOR PUBLICATION OF PROJECT. This project was carried out in the lithographic area of a metal packaging company, where unplanned downtime constitutes a critical restriction for operational efficiency. The objective is to reduce downtime by 30%, lowering the weekly average from 278 hours to 242 hours, in order to optimize resource use, decrease non-quality costs, and ensure a continuous production flow. The hypothesis states that by identifying root causes and implementing sustainable solutions, it is possible to increase line availability. To achieve this, the DMAIC methodology was applied, using tools such as FMEA, the 5 Whys technique, capacity analysis, and hypothesis testing. The diagnosis revealed that the main factors were related to inadequate operating speeds depending on sheet format, the lack of standardized calibration in the stacker, and the absence of detailed records that limited data analysis. The results show a 30% reduction in unplanned downtime, a 15% increase in line efficiency, a 59% decrease in non-quality costs, a 57% reduction in sheet waste, and an 8% increase in operational compliance. Keywords: DMAIC, sustainability, unplanned downtime, efficiency, lithography.