The Increasing Overall Equipment Effectiveness of High Density Polyethylene Pipe Manufacturing

Abstract

The objective of this research is to enhance the manufacturing process of High-Density Polyethylene pipe to minimize waste during production and enhance Overall Equipment Efficiency. The performance rate has been improved to meet the required amount of raw material for the plastic molding machine. This improvement has been achieved by implementing the DMAIC operational framework, which is based on the Six Sigma theory. In addition to process capability analysis techniques, brainstorming approaches, the use of seven quality tools, and ABC analysis, specific efforts have been made to reduce the loss of raw materials by 1.5 % and enhance Overall Equipment Efficiency by 2.5 % in the target of the case of production lines. The root cause analysis has determined that the installation of machining controller systems for thickness pipe is a mandatory activity in the operation.  There has been an encouragement to reduce the amount of raw material being flowed into the hopper, which leads to an increase in machine performance rate and also helps defend against defects in product quality. The improvement technique has utilized a Programmable Logic Controller (PLC) to regulate the actuator and carry out input data from measuring devices at the rolling piping section in the final process. Consequently, this activity has the potential to significantly decrease the amount of raw material by 2.5% and simultaneously enhance the Overall Equipment Efficiency by 4.4 %. This accomplishment has successfully achieved the objective of enhancing efficiency and productivity in the operations of the sample process case.