The Reduction of Production Delay in Vape Manufacturing Through Process Improvement

Abstract

The study aims to help Vape Manufacturing Company minimize the production delay by improving the existing production processes. The General Manager, who is also the company's owner, identified delay as the number one concern. The researcher uses the Process Capability Index (CPI) to statistically measure the process capability to justify the existing problem of the company. Also, to determine and divide into parts the potential causes of the problem, the researcher constructed and conducted a Root-Cause Analysis and survey. The survey results in ere treated using Weighted Mean and Chi-square Test for Associations and underwent validation by the General Manager.

The following were identified as the 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 motion during 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, Facilities Planning, and Layout, etc.

The proposed solutions were the following:(1) One-month 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 terms of the product cost or an increase of 12.40% in their profit per product or more.