Reduction production loss in the packaging box production by applying lean manufacturing practices

This industrial research project aims to reduce waste in the coffee packaging production process. Currently, the company reports and addresses issues on a monthly basis, with limited analysis of specific machines and waste. This limits their ability to identify and address the actual problems. To overcome this, Lean Tools, specifically Value Stream Mapping (VSM), are utilized to visualize the overall production efficiency and identify arising issues for improvement. Additionally, the project incorporates the analysis of the 7 Wastes. In this specific case study, the identified problem being addressed is in the packing process, specifically the inspection of items. The improvement approach involves reducing non-value-added activities that lead to issues such as bottle necks and waiting times. The study begins with understanding the work processes for each step and collecting data on inspection time. By applying the ECRS principle to balance the production line, the project achieves a reduction in inspection time from 193 seconds to 145.3 seconds, representing a 24 percentage improvement. The overall production line efficiency increases from 60.80 percentage to 79.309 percentage.