Enhancing Quality Control Through the Design and Implementation of an Impact Tester Tool

Every manufacturing company encounters various defects that have a negative impact on process efficiency, the company's reputation, and its profitability. The research was conducted at Primepack Technologies Inc., a manufacturer of plastic transportation packaging, with an emphasis on defect reduction. After conducting face-to-face interviews and observations in the production department, the researchers evaluated the thermoforming process and determined that defects occurred frequently. The researchers analyzed the occurrence of defects using a Pareto Chart, which reveals that the defects are related to bridging, rounded, holes, and narrow walls. Using the Fishbone diagram and Why-Why analysis, the researchers determined that the fundamental cause is the excessive fragility of thermoforming machine materials. With the fundamental cause identified, the researchers were able to determine that the lack of quality control equipment for testing the brittleness of the material was the primary reason for the high rate of defects. In accordance with this, the researchers proposed the design and development of an impact tester to have a positive impact on defect reduction. The proposed prototype intends to evaluate the quality of the polypropylene material under an impact, providing visual results, and regulating the mass production of defective sheets that the extrusion process may produce. This prototype serves as a quality control instrument in which the sheets are tested prior to mass production, thereby enhancing the company's reputation and ensuring optimal performance.