Lean application for waste reduction in Big Apple Packaging, Inc. / by Nhel Patrick A. Francisco and Angel Nina A. Soriano.

Thesis (Bachelor of Science in Industrial Engineering) Cavite State University

College of Engineering and Information Technology (CEIT)

FRANCISCO, NHEL PATRICK A. and SORIANO, ANGEL NINA A. Lean Application for Waste Reduction in Big Apple Packaging, Inc. Undergraduate Thesis. Bachelor of Science in Industrial Engineering. Cavite State University, Indang, Cavite. June 2022. Adviser: Mr. Harry D. Ednacot Jr.

The study was conducted to reduce the waste in Big Apple Packaging, Inc.'s production process through the application of lean manufacturing tools and techniques from October 2020 to May 2022. Specifically, this study aimed to: (1) define the current state of the company's production process; (2) identify existing waste/s in the production process; (3) determine and analyze the root causes of the identified wastes; (4) introduce improvements that could be implemented for waste reduction; (5) evaluate the results of the implementation; and (6) compare the current state and future state of the company's production process. In order to accomplish the stated objectives, the Define-Measure-Analyze-Improve-Control (DMAIC) methodology was administered. In the define phase, the current state of the company's production was defined including its background, the information flow of commands, the material flow from the supplier to the customer, the flow process chart of the production, its plant layout with flow diagram, and its production records. In the measure phase, through the utilization of time study analysis, the current state map of the company's production process was drawn. In order to identify the waste in the process, a survey questionnaire was administered, and data were collected from the employees. Based on the results of the weighted mean, the most existing wastes were determined: (1) motion; (2) inventory; and (3) defects. The amount of these three wastes were also defined and assessed. Through the use of fishbone diagram, potential root causes of these wastes were identified in the analyze phase. Several changes and improvements were proposed and implemented in the production process to deal with reduction of the existing waste. These improvements were based on various lean tools and techniques such as the 5S system, kaizen, and SMED. After the implementation, the time consumed by motion waste was reduced by 71.78 percent. A reduction of 22.31 percent was also obtained for the inventory waste, while the defects rate was obtained at 1.86 percent, which was below the AQL of 2.5 percent. The future state map of the company's production process was also drawn and established with the improvement of the value-added time and non-value-added time. For the control phase, an action plan was developed for the company which includes four phases: (1) understanding of lean tools and principles; (2) defining the value stream; (3) promotion of continuous improvement; and (4) standardization. Furthermore, it could be recommended to consider other lean techniques and tools for additional improvement, as well as to conduct the implementation for at least one month duration in order to obtain more satisfactory results.

Submitted copy to the University Library. 08/03/2022 T-9154