Abstract
This study applied the DMAIC (Define, Measure, Analyze, Improve, Control) methodology to improve the operational efficiency of a facility’s bottle cleaning process. The Define Phase identified critical issues, including a high rework rate (15%), inconsistent cleaning quality (84% efficiency), and excessive water and detergent consumption. The Measure Phase established baseline data to quantify these inefficiencies. Root causes were identified in the Analyze Phase using a Fishbone Diagram and Failure Mode and Effects Analysis (FMEA), highlighting manual detergent dosing, unstable wash temperatures, lack of standard operating procedures (SOPs), and inconsistent employee performance as major contributors. During the Improve Phase, remedies that were specific to the problem were put into place. These included automating the delivery of detergent and controlling the temperature, adding real-time monitoring, updating standard operating procedures (SOPs), and giving employees more training. Because of this, the cleaning efficiency went up to 92%, the rework rate went down to 7.5%, and the inspection pass rate went up to 92%. Resource usage decreased significantly – detergent by 23% and water by 20% – resulting in annual cost savings of $23,404.24. These gains were sustained through the Control Phase via continuous monitoring, regular audits, and periodic staff retraining. The project shows that DMAIC may help improve operations and lower costs in a way that lasts. It gives other plants a model to follow if they want to improve their manufacturing processes while making them better for the environment and quality. Combining automation, data collection, analysis, and a standardized workflow within a framework for improvement led to rapid gains and long-term process control.