Enhancing operational efficiency through overall equipment efficiency optimization and Kaizen initiatives.

Area of Science:

• Industrial Engineering
• Operations Management
• Manufacturing Systems

Background:

• Low efficiency in carton production lines impacts operational performance and profitability.
• Optimizing manufacturing processes is crucial for competitiveness in the packaging industry.
• Overall Equipment Effectiveness (OEE) is a key performance indicator for manufacturing efficiency.

Purpose of the Study:

• To investigate the root causes of low efficiency in a carton production line.
• To calculate and analyze Overall Equipment Effectiveness (OEE) for key machinery.
• To implement a cost-effective solution to enhance production line efficiency.

Main Methods:

• The Define, Measure, Analyze, Improve, Control (DMAIC) approach was employed.
• Six Sigma principles, including Kaizen, fishbone diagrams, and 5W+1H, were utilized.
• Average OEE was calculated across four machines over 12 shifts, followed by value stream mapping.

Main Results:

• The proposed cost-effective method significantly improved OEE.
• Finished goods line efficiency increased by 29%, and corrugated boards line efficiency rose by 9%.
• Value stream mapping confirmed improvements in operational performance.

Conclusions:

• Implementing OEE analysis and Six Sigma methodologies effectively addresses production line inefficiencies.
• Enhanced OEE positively impacts overall operational performance, including efficiency, power usage, cycle time, and equipment repair.
• Continuous improvement strategies are vital for sustained manufacturing excellence in the carton industry.