Management Analysis of Industrial Production Losses by the Design of Experiments, Statistical Process Control, and Capability Indices

The machine stops caused by various breakdowns, rupture of raw materials, production changes, scheduled maintenance and stops related to human resources management generate an important production loss in the company. Our case study is done in a company that manufactures polyethylene pipes with eight production lines. They stop frequently because they undergo external control factors and noise factors. The method of experi- mental design that relies on statistical surveys is applied to production loss allows us to observe the action of each factor on the loss of production and their interactions of these factors combined in pairs on this process. Analysis of results shows the dominance of controllable or uncontrollable factor on the loss of production. This is illus- trated by response surfaces and ISO responses lines were derived by mathematical modelling. Solutions are proposed to improve continuous production, reduce waste and scrap and therefore increase profitability of company.