Reducción del tiempo de cambio de formato en una línea de envasado de botellas

Abstract

This project aimed to reduce the high format changeover times on a bottle filling machine at a brewery located in Guayaquil. The DMAIC methodology (Define, Measure, Analyze, Improve, and Control) from Lean Six Sigma was applied, allowing the project to be developed in a structured manner, from problem definition to controlling the implemented improvements. During the measurement phase, process variables were identified and data was collected at each format change. Subsequently, in the analysis stage, the data was evaluated both quantitatively and qualitatively, identifying the root causes of delays. Based on these results, solutions aimed at standardization and time reduction were implemented, including the application of SMED, visual management through QR codes, the unification of mechanical parts to reduce adjustments, and the development of a Poka Yoke to facilitate the operator's work and prevent errors. The format change over time was reduced from 135 to 100 minutes. Additionally, the project generated positive impacts on the three pillars of sustainability: a reduction of 0.3 hectoliters of water, the elimination of safety incidents, and an estimated annual savings of $14,000. Keywords: DMAIC, SMED, visual management, QR, Poka Yoke, Brewery