Improving Efficiency in the Random Sampling Process: A Case Study of Pouch Products at Raw Material Receiving and Warehouse
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Abstract
The objective of this work was to improve efficiency in the random sampling process of pouch products by applying the MIL-STD-105E and switching rules in process improvement. DMAIC, which is the 5 steps of Six-sigma, was applied. In the Define (D) phase, in 2020 it was found that the average sampling sizes of pouch products were 7,438 bags/month and 110,641 bags/month at the raw material receiving and warehouse departments. These records were higher than the target goal of the company, resulting in a lost sales value of approximately 22,459.40 Baht/month. In Measure (M) phase, 3 main problems in the sampling procedure were observed, namely, not systematic working culture, no sampling plan standard, and too many random sample sizes. Therefore, the root cause analysis in Analyze (A) phase was analyzed by using the design of the experiment in combination with ECRS, MIL-STD-105E, and switching rules. Those root cause factors were then experimented and the optimum condition was used in a further step. In Improve (I) phase, it was found that the average sampling sizes of pouch products were reduced to 5,147 bags/month and 48,425 bags/month at the raw material receiving and warehouse departments resulting in the advantage of the sales value of production approximately 6,562.92 baht/month. Consequently, this could be able to reduce the number of employees by 2 people. In addition, in terms of Control (C) phase, the process of creating a system for sustainable control was conducted and shared with employees by One Point Lesson (OPL).
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