Process Optimization in a Condiment SME through Improved Lean Six Sigma with a Surface Tension Neural Network

IF 2.8 4区 工程技术 Q2 ENGINEERING, CHEMICAL
Processes Pub Date : 2024-09-17 DOI:10.3390/pr12092001
Manuel Vargas, Rodolfo Mosquera, Guillermo Fuertes, Miguel Alfaro, Ileana Gloria Perez Vergara
{"title":"Process Optimization in a Condiment SME through Improved Lean Six Sigma with a Surface Tension Neural Network","authors":"Manuel Vargas, Rodolfo Mosquera, Guillermo Fuertes, Miguel Alfaro, Ileana Gloria Perez Vergara","doi":"10.3390/pr12092001","DOIUrl":null,"url":null,"abstract":"This study offers an innovative solution to address performance issues in the manufacturing process of garlic salt within a condiment-producing SME. A hybrid Lean/Six Sigma model utilizing a Surface Tension Neural Network (STNN) was implemented to control temperature and relative humidity in real-time. The model follows the Define, Measure, Analyze, Improve, Control (DMAIC) methodology to identify root causes and correlate them with waste. By integrating statistical tools, artificial intelligence, and engineering design principles, alternative solutions were evaluated to minimize waste. This document contributes to existing knowledge by demonstrating the integration of an STNN with the Lean/Six Sigma framework in condiment production, an area with limited empirical research. It underscores the benefits of advanced AI technologies in enhancing traditional process optimization methods. The STNN model achieved 97.31% accuracy for temperature classification and 97.37% for humidity, outperforming a Naive Bayes model, which attained 90% accuracy for both. The results showed a 3.15% increase in yield, saving 39.7 kg of waste per batch. Additionally, a 2.13-point improvement at the Six Sigma level was achieved, reducing defects per million opportunities by 551.722. These improvements resulted in significant cost savings, with a reduction in waste-related losses amounting to USD 1585 per batch. The study demonstrates that incorporating artificial intelligence into the Lean/Six Sigma methodology effectively addresses the limitations of traditional statistical methods. Significant improvements in yield and waste reduction highlight the potential of this approach, enhancing operational efficiency and profitability, and fostering sustainable manufacturing practices critical for SMEs’ competitiveness and sustainability in the global market.","PeriodicalId":20597,"journal":{"name":"Processes","volume":null,"pages":null},"PeriodicalIF":2.8000,"publicationDate":"2024-09-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Processes","FirstCategoryId":"5","ListUrlMain":"https://doi.org/10.3390/pr12092001","RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q2","JCRName":"ENGINEERING, CHEMICAL","Score":null,"Total":0}
引用次数: 0

Abstract

This study offers an innovative solution to address performance issues in the manufacturing process of garlic salt within a condiment-producing SME. A hybrid Lean/Six Sigma model utilizing a Surface Tension Neural Network (STNN) was implemented to control temperature and relative humidity in real-time. The model follows the Define, Measure, Analyze, Improve, Control (DMAIC) methodology to identify root causes and correlate them with waste. By integrating statistical tools, artificial intelligence, and engineering design principles, alternative solutions were evaluated to minimize waste. This document contributes to existing knowledge by demonstrating the integration of an STNN with the Lean/Six Sigma framework in condiment production, an area with limited empirical research. It underscores the benefits of advanced AI technologies in enhancing traditional process optimization methods. The STNN model achieved 97.31% accuracy for temperature classification and 97.37% for humidity, outperforming a Naive Bayes model, which attained 90% accuracy for both. The results showed a 3.15% increase in yield, saving 39.7 kg of waste per batch. Additionally, a 2.13-point improvement at the Six Sigma level was achieved, reducing defects per million opportunities by 551.722. These improvements resulted in significant cost savings, with a reduction in waste-related losses amounting to USD 1585 per batch. The study demonstrates that incorporating artificial intelligence into the Lean/Six Sigma methodology effectively addresses the limitations of traditional statistical methods. Significant improvements in yield and waste reduction highlight the potential of this approach, enhancing operational efficiency and profitability, and fostering sustainable manufacturing practices critical for SMEs’ competitiveness and sustainability in the global market.
利用表面张力神经网络改进精益六西格玛,优化调味品中小企业的流程
本研究提供了一个创新解决方案,以解决一家生产调味品的中小企业在大蒜盐生产过程中的绩效问题。利用表面张力神经网络(STNN)实施了一个混合精益/六西格玛模型,以实时控制温度和相对湿度。该模型采用定义、测量、分析、改进、控制(DMAIC)方法来确定根本原因,并将其与浪费联系起来。通过整合统计工具、人工智能和工程设计原则,对替代解决方案进行了评估,以最大限度地减少浪费。本文件展示了 STNN 与精益/六西格玛框架在调味品生产中的整合,为现有知识做出了贡献。它强调了先进人工智能技术在增强传统工艺优化方法方面的优势。STNN 模型的温度分类准确率为 97.31%,湿度分类准确率为 97.37%,优于 Naive Bayes 模型,后者的准确率为 90%。结果表明,产量提高了 3.15%,每批可节省 39.7 公斤废物。此外,在六西格玛水平上实现了 2.13 分的改进,每百万次机会中的缺陷减少了 551.722 次。这些改进极大地节约了成本,每批次与废物有关的损失减少了 1585 美元。这项研究表明,将人工智能融入精益/六西格玛方法,可以有效解决传统统计方法的局限性。产量和浪费减少方面的显著改善凸显了这一方法的潜力,提高了运营效率和盈利能力,并促进了对中小企业在全球市场上的竞争力和可持续性至关重要的可持续生产实践。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
求助全文
约1分钟内获得全文 求助全文
来源期刊
Processes
Processes Chemical Engineering-Bioengineering
CiteScore
5.10
自引率
11.40%
发文量
2239
审稿时长
14.11 days
期刊介绍: Processes (ISSN 2227-9717) provides an advanced forum for process related research in chemistry, biology and allied engineering fields. The journal publishes regular research papers, communications, letters, short notes and reviews. Our aim is to encourage researchers to publish their experimental, theoretical and computational results in as much detail as necessary. There is no restriction on paper length or number of figures and tables.
×
引用
GB/T 7714-2015
复制
MLA
复制
APA
复制
导出至
BibTeX EndNote RefMan NoteFirst NoteExpress
×
提示
您的信息不完整,为了账户安全,请先补充。
现在去补充
×
提示
您因"违规操作"
具体请查看互助需知
我知道了
×
提示
确定
请完成安全验证×
copy
已复制链接
快去分享给好友吧!
我知道了
右上角分享
点击右上角分享
0
联系我们:info@booksci.cn Book学术提供免费学术资源搜索服务,方便国内外学者检索中英文文献。致力于提供最便捷和优质的服务体验。 Copyright © 2023 布克学术 All rights reserved.
京ICP备2023020795号-1
ghs 京公网安备 11010802042870号
Book学术文献互助
Book学术文献互助群
群 号:481959085
Book学术官方微信