IMPROVING PROCESS CAPABILITY IN PLASTIC FILM THICKNESS CONTROL
DOI:
https://doi.org/10.62985/j.huit_ojs.vol26.no3E.542Từ khóa:
Gauge Repeatability and Reproducibility (GR&R), measurement system analysis, DMAIC (Define, Measure, Analyze, Improve, Control), process capability, blown-film extrusion.Tóm tắt
This study aims to deploy the Six Sigma DMAIC framework to improve process capability in plastic film-thickness control, which is applied to a 31 µm LLDPE blown-film extrusion process. The crossed Gauge Repeatability and Reproducibility method is ultilized to confirm measurement system adequacy in this study. The baseline analysis of 260 observations reveals Cp = 1.07, Cpk = 0.78, and a 5.8% out-of-tolerance rate; which is shown that the process is not properly centered within the specified engineering boundaries. Notably, performance improves to Cp = 1.32, Cpk = 1.13, while significantly reducing the defect rate to 0.9%, thanks to the targeted enhancements, which include parameter stabilization, consistent resin feeding, and improved calibration. Accordingly, this study emphasizes the significance of statistical-driven process control and dependable measurement methods in addition to mechanical optimization. Therefore, for extrusion operations suffering from continuous thickness instability, the combined application of measurement systems analysis, SPC, root-cause verification, and standardized control techniques offers a workable foundation for achieving more stable and economically viable output.
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