Production Optimization in the Packaging and Inspection Process at a Thermoforming Area

Abstract

This research is conducted in a manufacturing packaging company that makes the packages (plastic trays) for medical device companies. It is intended to increase the packaging and inspection production line by considering a new layout design and utilization of the resources. The methodology used in this project was the Lean Six Sigma including the DMAIC model. The objective was to increase the total production by 10%. Results showed an incremental percent of 15.25%. The task time for the production line for packaging and inspection was proficiently decreased. Within the new arrangement the company has the capability of a crew reduction of an average of 4.5 unnecessary operators. After calculating the cost opportunity, in terms of incremental output, the saving was $24,246 plus the applied personnel reduction saving was $60,000. The total savings for the implemented project of $84,246 was applied to direct labor costs.