An Application of Six Sigma for Optimality of Medium Density Fiberboard Production

Abstract

During the production process of MDF, there is a high level of internal bond (IB) variation. This results in the waste of out-of-standard IB values that account for 0.38 % with damage value over 1 million baht/year. The company required products with fewer volatile compounds from formaldehyde adhesives, focusing on reducing the amount of adhesive but still being strong according to IB-specification which will reduce the cost of production by about 20 − 30 million baht/year. The results of wood sampling and IB testing were divided into 6 areas, namely IB1-IB6. It was found that most of the data were symmetrical except for the IB5 data as the area where the most variation occurs. The distributions of the IB1 and IB6 data showed relatively low variability compared to data from other areas. IB1 - IB6 values were normal distribution, expect for IB5. Process capacity in IB2 was relatively high compared to IB from other areas. From the Correlation Matrix and Correlation Map, it was found that the variables that influenced the IB were Press Factor, % Dosing Glue, Heat Circuit1, Primary Circuit Intel and % Mc After Gluing. To conduct the experiment and find the best variable conditions by 25-2 - Factorial Design (Resolution: III). It was found that Glue = 7.4, Heat1 = 234.4, and Press = 6.5 would give IB = 0.88 which was closest to target (0.7). Glue = 7.1, Heat1 = 233.2, and Press = 6.48 would give IB = 1.15 which was the highest value. Results of production conditions at optimum or maximum that can be generalized from Rayleigh Method Dimensional Analysis was found that at the levels of 7.85, 254.28 and 257.70 of Glue, Heat1 and PrimCirIn, the target response (IB) was 0.7. and at the levels of 8.07, 233.35 and 281.60 of Glue, Heat1 and PrimCirIn resulted in a response value (IB) of 1.27.