Process Improvement for PET Bottles Manufacturing Company Using Six Sigma Approach

Abstract

Rejection in production processes cannot be ignored in industries in general, and in manufacturing organizations in particular. Six sigma has been considered an organized and scientific approach for the last few decades in order to reduce the number of rejections in processes. This paper has focused the injection modeling process in PET bottles manufacturing industry in Pakistan. The paper aims to reduce the number of rejected products produced during the injection molding process and highlight the significant factors and their level that severely affect the molding process. Different type of defects were observed in the injection molding process. Statistical approach using hypothetical analysis and experimental design techniques were used to conclude significant factors and their levels. Injection pressure, melting temperature, and resin type were observed as the most significant factors that affect the number of defective products produced during the PET bottles manufacturing. The joint interaction effect of pressure and temperature was also significant in comparison to all other interaction effects during this process.