Productivity Improvement of Carton Manufacturing Industry by Implementation of Lean Six Sigma, ECRS, Work Study, and ۵S: A Case Study of ABC Co., Ltd.

The objective of this study is to improve productivity by means of lean six sigma, ECRS, work study, and ۵S in carton manufacturing industry. The study was conducted from November ۲۰۱۷ to August ۲۰۱۸ from a case study of ABC Co., Ltd. The data were collected from managers and supervisors and the problems were analyzed by brainstorming, cause and effect diagram, and pareto chart. Referring to the results, it was found that production problems occurred from a delayed process in cutting and Die-cut department, messy area in warehouse, delayed and erroneous transportation. Considering the measurement process, the measurement method could be changed from using hand to using pattern. The standard time was then reduced from ۲۱.۱۷ minutes per ۱۰۰ pieces to ۱۸.۱۰ minutes per ۱۰۰ pieces, accounting for ۱۴.۵۰ percent of improvement. The lost cutting time was caused by excess movement of worker while sitting and working. So, when the movement was changed from sitting to standing, the worker felt less exhausted and could reduce the standard time from ۱۹.۳۲ minutes per ۱۰۰ pieces to ۱۵.۰۵ minutes per ۱۰۰ pieces, accounting for ۲۲.۱۰ percent of improvement. The messy in warehouse had caused erroneous retrieval as well as delayed and erroneous transportation. Once it was improved by cleaning, classifying products and areas with sign boards, the results showed that the cost of loss was reduced from ۴۵,۹۰۰ THB per quarter to ۲۱,۶۰۰ THB per quarter, accounting for ۵۲.۹۴ percent of improvement. Employee satisfaction level was increased from ۳.۲۰ to ۴.۶۰, accounting for ۴۳.۷۵ percent of improvement.

Keywords:

Brainstorming , Cause and Effect Analysis , ECRS , Lean Six Sigma , Productivity , Work Study , ۵S , Continuous Improvement