Setup Time Reduction of Four Corner Folding Paperboard Box Process by Quick Changeover Technique

Abstract

The printing and packaging industry has been growing rapidly and high competition. To respond the demands from customers according to the size of the business, the manufacturers have to improve themself to enhance production efficiency. The objective of this research was to reduce the setup time of a four corner folding paperboard box process, which was a time consuming tasks and had many working steps in the process of installation, adjustment and test. This work started analyzing work process with flow process chart and using quick changeover technique as a guideline to improve the process. The research found that, the previous folding paperboard box process has the average machine setup time at 266 minutes, which the target of setup time required was 240 minutes. From the development of the working process and convert the setting on the machine to activities performed outside the machine. The average machine setup time after the improving was decreased from 266 minutes to 160 minutes. This improvement was accounted for 40 percent of setup time decreased, which was below the target setup time. Therefore, the setup time was reduced and the operational efficiency of the production process was met the satisfaction.