Enhancing Process Stability in BOPP Film Production: A Case Study on DMAIC-Based Reduction of Coefficient of Friction Defects

Abstract The growing competitiveness in the industrial sector has driven the adoption of structured methods to reduce losses and optimize production processes. This study focused on the issue of elevated coefficient of friction (COF) in biaxially oriented polypropylene (BOPP) films, a characteristic that compromised product quality and affected the Overall Equipment Effectiveness (OEE) index. The objective was to apply the DMAIC methodology (Define, Measure, Analyze, Improve, and Control) to reduce occurrences of COF outside the specified limits and enhance operational performance. The work was carried out through a case study in an industry in the sector, using tools such as the Ishikawa diagram, the 5 Whys technique, EWMA control charts, GRIP analysis, and the 5W2H action plan. The analyses indicated that the main cause of the problem was associated with failures in the winding systems, which resulted in excessive reel hardness. Corrective actions included preventive maintenance, parameter standardization, and operator training. The results showed a significant reduction in COF and greater process stability, with a positive impact on OEE. It is concluded that the structured application of DMAIC effectively contributed to solving the problem and consolidating continuous improvement practices.