Análisis de la variabilidad en los procesos productivos en la empresa de calzado Pool Sport mediante la metodología Six Sigma

Abstract

The research project focuses on analyzing the variability present in the production processes at POOL SPORT, with the objective of proposing an action program to reduce defects using Six Sigma tools and methodologies. These are presented in a list designed to identify the main improvement alternatives, aimed at addressing critical issues, thereby reducing defects in the operational area, decreasing variability, improving the quality of the final product, and increasing customer satisfaction. Through bibliographic-documentary research, field research, and applied research, all the information and data were collected, including the historical sales data for the period (July - December 2023). An ABC analysis was performed, allowing the identification of the most profitable product. Based on this model, information was gathered, followed by the creation of process diagrams to understand the current situation of the company and the current working method employed at the facilities. Tools such as interviews and Pareto diagrams were used to identify defects in the operational area, such as: unstitched pieces 26%, adhesive stains 20.9%, pieces with cutting defects 13.2%, poorly stitched labels 12.4%, irregular cuts 10.9%, loose seams 5.8%, incorrect soles 5.8%, and defective stamping 5.0%. These defects were associated with factors related to labor and raw materials identified through cause-and-effect analysis and the FMEA matrix. Once the critical processes (stitching and sole attachment) and potential defects (adhesive stains and unstitched pieces) were identified, with quality levels for the processes at 2.46σ and 2.70σ respectively, as well as Yield efficiencies of 83.1% and 88.5% respectively, the negative situation of the processes was exposed. Finally, improvement proposals based on the DMAI analysis were developed, where alternatives were established that should be maintained over time through the records and programs outlined in the Control (C) stage.