Productivity Improvement of Corrugated Carton Industry By Implementation of Continuous Improvement, 5s, Work Study, and Muda Elimination: A Case Study of Xyz Co., Ltd.
Piyachat Burawat
Piyachat Burawat, Department of Business Administration, Rajamangala University of Technology, Thanyaburi Pathumthani, Thailand.
Manuscript received on 01 September 2019 | Revised Manuscript received on 10 September 2019 | Manuscript Published on 23 September 2019 | PP: 178-183 | Volume-8 Issue-5C, May 2019 | Retrieval Number: E10260585C19/19©BEIESP | DOI: 10.35940/ijeat.E1026.0585C19
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Abstract: The purpose of this study is to make productivity better by means of 5S, work study, and Muda elimination in corrugated carton industry which was conducted from November 2018 to March 2019 from a case study of XYZ Co., Ltd. The data were collected from managers and supervisors and the problems were analyzed by brainstorming together with cause and effect diagram. Crucial problems of production occurred from human errors, i.e. production employees ignored to check the availability of machines before operating the machine, production employees neglected to prepare materials for next orders while machines operating, and warehouse employees randomly checked the humidity before the storage of corrugated sheet papers. Employees could be trained about production process, machine operation, quality inspection, and planning process. The production process could be changed from operating machine without checking machine availability and removing material remains in the machine to check availability and removing materials remains in the machine before operating new purchasing order. The output was then increased from 2,000 to 2,300 ton per month, accounting for 15.00 percent of improvement. The defect was reduced from 160 to 140 pieces per month, accounting for 12.50 percent of improvement. Regarding the storage process, it could be changed from random check of humidity to check of humidity every time. The messy in warehouse had caused mixing of wet or damp raw materials with good quality raw materials. Once it was improved by cleaning, classifying materials, products and areas with sign boards, the results showed that the materials and products were easier to find and product quality was increased. Company launches 5S policy and doing 5S activities continuously twice a month. The findings presented that the number of employees who neglected to comply with the organizational regulations was reduced from 6 to 2 persons, accounting for 66.67 percent of improvement.
Keywords: Muda Elimination, Productivity, 5S, Work Study.
Scope of the Article: Industrial Engineering