Productivity improvement using industrial engineering tools

Minimizing the number of defects is important to any company since it influence their outputs and profits. The aim of this paper is to study the implementation of industrial engineering tools in a manufacturing recycle paper box company. This study starts with reading the standard operation procedures and analyzing the process flow to get the whole idea on how to manufacture paper box. At the same time, observations at the production line were made to identify problem occurs in the production line. By using check sheet, the defect data from each station were collected and have been analyzed using Pareto Chart. From the chart, it is found that glue workstation shows the highest number of defects. Based on observation at the glue workstation, the existing method used to glue the box was inappropriate because the operator used a lot of glue. Then, by using cause and effect diagram, the root cause of the problem was identified and solutions to overcome the problem were proposed. There are three suggestions proposed to overcome this problem. Cost reduction for each solution was calculated and the best solution is using three hair drier to dry the sticky glue which produce only 6.4 defects in an hour with cost of RM 0.0224.