The Efficiency of the Proposed Process Flow in a Vape Manufacturing Company: An Analysis

Abstract

The study aims to help Vape Manufacturing Company reduce the production delay and increase its efficiency by improving the existing production processes. The General Manager, also the company’s owner, identified delay as the number one concern. The researcher uses Process Capability Index (CPI) to statistically measure process capability to justify the existing problem of the company. In addition, to determine and divide the problem's potential causes into parts, the researcher constructed and conducted a Root-Cause Analysis and survey. The researcher treated survey results using Weighted Mean, Analysis of Variance, and Pearson Correlation Coefficient and underwent validation by the General Manager. The paper identifies the following as significant factors causing delay: (1) No proper training of machine operators, (2) Lack of workforce, (3) Long set-up time of machines, (4) Not finalized product design, (5) Inappropriate production layout, and (6) Excessive motions during the process and interrupted operations because of the “inserted items”. Hence, the primary applications utilized in this study to reduce delay were various process methodologies; Time and Motion Study, Process Capability Test, Cause and Effect Analysis, and Facilities Planning and Layout. The proposed solutions were the following: (1) A month-long training program for the newly hired machine operators, (2) Hiring skilled workers, (3) Improved Plan Sheet, (4) Improved Process Flow, and (5) Improved production layout. Implementation of these proposed solutions could save 4.54 minutes per product or Php81.72 in production cost or an increase of at least 12.40% in their profit per product.