Enhancing Carbonated Beverage Bottle Packaging: Reducing Changeover Time and Machine Setup in PET5 Production

Abstract

 This research aims to enhance the spare parts replacement process and machine setup for large-scale carbonated beverage bottle packaging in the PET5 production line to improve production efficiency and reduce time losses. The research methodology consists of four stages: (1) studying the packaging process, (2) collecting data on time losses occurring during operations, (3) analyzing the root causes of inefficiencies using the Why-Why Analysis technique, and (4) implementing process improvements. The improvement strategies were applied to two packaging machines. For Packaging Machine 1, enhancements included implementing identification markings on spare parts, designing auxiliary equipment to prevent bottle tipping, and establishing standardized procedures for conveyor belt and air-blowing unit adjustments. For Packaging Machine 2, modifications focused on refining the guide rail adjustments at the front and rear of the machine, along with developing auxiliary equipment to enhance measurement accuracy. The results showed a reduction in the changeover time for Packaging Machine 1 from 90 to 76 minutes (15.5%) and for Packaging Machine 2 from 60 to 48 minutes (20%), contributing to increased production capacity and an estimated additional revenue of 5,832,000 Baht per year. The proposed methodology is scalable and can be applied to other production lines using similar machinery, offering a systematic approach to operational efficiency improvement.