Reducing Changeover Time in the Plastic Injection Process: Case Study

Abstract

This research focuses on reducing the changeover time of the plastic injection process and analyzing the economic benefits of improvement. It starts with identifying and analyzing the problems that occur in the changeover process systematically, using the cause-and-effect mapping tool to identify the causal factors and the Why-Why Analysis to evaluate the root causes of the problems. The work correction and improvement approach is developed based on the ECRS principle. The results of the operation show that the changeover time is significantly reduced from 3,960 seconds to 3,582 seconds, which is a reduction of 378 seconds, or 9.54 percent. In addition, the economic analysis indicates that labor costs can be reduced by 348,872.8 baht per year, and the project has a break-even point of only 7 days. This study demonstrates the effectiveness of applying the work and time study to increase productivity and create tangible economic benefits.