Propuesta de mejora en el proceso de curado en una empresa metal mecánica en el área de pintura aplicando el ciclo DMAIC

Abstract

This paper proposes improvement strategies for the electrostatic painting area of a metalworking company located in Quito. Currently, this process has a rework rate exceeding 20% for several products, generating additional costs, loss of efficiency, and negatively impacting coating quality. Forty-four products manufactured by the company were analyzed, focusing on the 66% that presented defects such as bubbles, loss of adhesion, irregular finishes, and a high rework rate. To address these problems, the Lean Six Sigma methodology was applied using the DMAIC cycle. In the Define phase, the problem was identified using production history data from 2022 to 2024, selecting 29 representative products with high volumes and recurring defects. In the Measure phase, key data such as curing time, oven temperature, and rework percentage were collected. This information allowed for the establishment of an analytical basis and the definition of process performance indicators. During the Analyze phase, tools such as the Ishikawa diagram, Pareto analysis, and FMEA were used to identify the root causes of the most frequent defects. In the Improve phase, technical solutions were proposed, including the use of control charts, implementation of preventive maintenance, process standardization, and acquisition of key equipment to ensure quality. Finally, in the Control phase, actions such as the use of standardized formats, maintenance plans, and technical quality control forms were implemented to maintain longterm process stability and strengthen continuous improvement. The expected outcome is a significant reduction in rework, improved finish quality, and increased thermal and operational efficiency of the curing oven, thereby benefiting the company's productivity and competitiveness