Development of a self-cleaning magnetic filter using the DMADV methodology and CAD design for mitigating ferrous contamination in the rice industry

Abstract

In the world of manufacturing and food production, plant design and mass production of various processes have been fundamental. In fact, this production environment fosters constant competition to offer products with better attributes. To meet quality parameters and satisfy customer needs, it is essential to maintain a high level of product protection while ensuring the safety and efficiency of industrial equipment.

Specifically, in the rice industry, one of the main risks in production is contamination by ferrous residues at different points along the production line. This not only jeopardizes the proper functioning of machinery but can also contaminate the final product. A common solution to this problem is the use of magnetic filters; however, their use can cause multiple injuries to operators and those who come into direct contact with them.

Using the Design-Measure-Analyze-Verify (DMADV) methodology, a solution is proposed with the objective of reducing both ferrous contamination and accidents caused by magnetic filters. The project evolves through the five stages of this methodology, beginning with an analysis of the problem related to ferrous contamination risks. Next, the target market was identified, which enabled the application of Critical to Quality (CTQ) techniques and the generation of brainstorming sessions to evaluate and develop a potential concept as a solution. This process facilitated the creation of a detailed design using Computer-Aided Design (CAD) tools, leading to a functional prototype of a self-cleaning magnetic filter. The prototype was tested in a national rice industry setting, allowing for verification and enhancement of its quality standards according to industrial design guidelines in engineering contexts.

The design and testing of the prototype demonstrated that the self-cleaning magnetic filter has significant potential to improve worker safety, enhance product quality, and reduce time and cost inefficiencies in the production process. Thanks to the DMADV methodology and the use of CAD tools, it was possible not only to address the issue of ferrous contamination and associated risks but also to develop an innovative and validated solution for the rice industry. This type of innovation contributes to optimizing industrial processes, improving both operational efficiency and the sector's competitiveness.