Lean Management is Used to Improve Efficiency in The Glass Bottle Filling Process of a Beverage Factory

Abstract

This study focuses on the packing process of a sample plant that mostly uses machines to pack glass bottle beverages, with overall machine efficiency serving as the primary indicator of machine efficiency throughout production. Because the factory wants to improve overall efficiency, a value stream map was created to identify the source of the entire glass bottle beverage packaging process, and a loss-finding activity was carried out by walking around and using lean concepts, such as the eight production process wastes, to help identify the problem. It was discovered that the major procedure with problems that can be resolved is the cap being caught at the Capper exit. This is a cap stuck problem, with the major issue occurring at the cap rail before entering the cap return cylinder. As a result, Why-Why analysis was done to determine the underlying cause of the problem, and preventive measures were implemented, such as the issue with the cap becoming caught at the cap rail before entering the cap return cylinder. The preventive action was to devise a detailed cleaning schedule so that the equipment could operate at peak efficiency. This reduces the problem of the cap being caught at the Capper exit by 34.48%, from 1.45% to 0.95%., significantly improving overall machine efficiency.