Enhancing operational efficiency through overall equipment efficiency optimization and Kaizen initiatives
Abu M. Fuad, Nusra Akter Takia, Hasin Ahmad Zafir, Omar Farrok
TL;DR
This case study improves carton production efficiency using OEE optimization and Kaizen, achieving significant gains in performance and resource use.
Contribution
A cost-effective method combining Six Sigma and Kaizen to enhance OEE in carton production lines.
Findings
OEE improved by 29% for finished goods and 9% for corrugated boards.
Value stream mapping confirmed the effectiveness of the implemented improvements.
Higher OEE values led to better efficiency, power usage, cycle time, and equipment repair.
Abstract
This case study aims to investigate the causes of low efficiency in a carton production line by calculating Overall Equipment Effectiveness (OEE). A typical carton factory has been chosen for this study, which has two production lines, namely finished goods and corrugated boards. The define, measure, analyze, improve, and control approach is applied while implementing Six Sigma principles such as Kaizen, fishbone diagrams, and 5W+1H as its systematic procedure. The analysis involves estimating four machines’ average OEE across 12 shifts. A cost-effective method is applied to resolve the problems that cause the lines to be less efficient. By applying the proposed method, the OEE becomes more efficient by 29% for finished goods and 9% for corrugated boards. Value stream mapping has been used to track the improvements. It is found that emphasizing higher OEE values enhances operational…
Click any figure to enlarge with its caption.
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23Peer Reviews
No public reviews on file for this paper yet. If you reviewed it on a platform where reviews are public (OpenReview, ICLR, NeurIPS, ICML), you can paste yours below so the community can read it here.
Videos
No videos yet. Explain this paper in a talk, walkthrough, or lecture? Add one.
Taxonomy
TopicsQuality and Supply Management · Management and Optimization Techniques · Product Development and Customization