Rediseño del proceso de producción y etiquetado de envases plásticos mediante integración de controles de calidad y automatización para la mejora del desempeño operativo de la línea de soplado

Abstract

Abstract: This research redesigns the production and labeling process for plastic containers on the SO14 line at Fadesa S.A. The project arises after detecting operational instability during the 2023-2024 cycle, reflected in 113 critical customer complaints. The diagnosis, based on the OEE indicator and Pareto analysis, identifies that reliance on manual inspection generates constant downtime and excessive return of HDPE resin to the mill due to adhesion and tightness defects. The methodology integrates quality tools such as Ishikawa and the "five whys" to structure a closed-loop technical solution. The improvement proposal implements a Siemens S7-1200 PLC controller, artificial vision sensors, and a leak verification system calibrated at 7 bar. This redesign replaces subjective operator criteria with an automatic rejection barrier that segregates non-conforming products in real time. The impact evaluation projects a 93% reduction in labeling defects, recovering availability and stabilizing performance. The results ensure compliance with the ISO 9001:2015 standard, transforming a reactive operation into integrated manufacturing.