ANALYSIS OF DEFECTS IN THE PRODUCTION PROCESS OF GRADE MAKROLON PLASTIC PELLETS TO ENHANCE EFFICIENCY AND PRODUCTION STANDARDS

Abstract

Abstract

This research analyzes production abnormalities in the manufacturing process of Makrolon-grade plastic pellets to enhance efficiency and production standards. The objectives are: (1) to identify the causes of abnormalities in the Makrolon-grade plastic pellet production process, (2) to develop operational guidelines for addressing these abnormalities, and (3) to evaluate the effectiveness of the implemented guidelines in resolving production issues. The study was conducted with 48 employees from the CPD production department at Covestro (Thailand) Co., Ltd. Research tools included fishbone analysis diagrams, developed operational guideline check sheets, and data recording forms for evaluating implementation results.

The findings indicate that the primary production issues include: (1) pellet contamination, black spots, and streaks, (2) color deviations from standard specifications, and (3) pellet clumping. The root causes stem from machinery settings, operational procedures, workforce practices, and raw material quality, particularly improper machine parameter settings, non-compliance with standard procedures, and inconsistent raw material quality. Implementing the revised operational guideline check sheets improved production efficiency and standards, significantly reducing defects such as burnt pellets, color inconsistencies, and black spots key factors affecting product quality.