LEAN TOOLS FOR CONTINUOUS IMPROVEMENT IN THE DEVELOPMENT OF AN IRREGULAR GREEN BLOCK

Resumen

This study presents the development of an irregular green block for interior non-structural partition applications through an integrated framework of design and continuous improvement tools. The methodology combined Quality Function Deployment (QFD), Poka-Yoke, Kaizen, and a suggestion-based feedback mechanism. In the first stage, customer requirements were identified through 388 valid surveys. Mechanical resistance, environmental value, affordability, and practical confidence were identified as the main design priorities. These requirements were translated into technical criteria through the House of Quality. Experimental validation included 21 formulations prepared with polylactic acid (PLA) and sugarcane bagasse. Processing temperature was maintained at 140 °C and specimen mass at 10 g. Bagasse concentration varied from 0% to 20%. Mechanical performance was evaluated through tensile testing of bone-shaped specimens, while structural characterization was carried out using FT-IR. The results showed a progressive reduction in tensile resistance as bagasse concentration increased. Pure PLA presented the highest resistance value at 4.20 MPa, while the 80% PLA–20% bagasse formulation reached 0.70 MPa. ANOVA confirmed statistically significant differences among formulations. The developed block was therefore reoriented toward interior non-structural partition applications.