ENHANCING NEST SEALING BLISTER UTILIZATION IN THE PACK-OUT PROCESS THROUGH BUSINESS PROCESS IMPROVEMENT AND LEAN MANUFACTURING IN A TOY COMPANY

Abstract

This research aims to implement business process improvement to evaluate the utilization of nest-sealing blister tools in a Toy Manufacturing Company pack-out process. The improvement is developed through implementing lean manufacturing to eliminate non-value added (NVA) activities and reduce lead time. The current process identifies a lead time and NVA time of 28,834 minutes and 21 minutes, respectively. To achieve the research objective, value stream mapping (VSM) is chosen as the tool to visualize the process waste to initiate an improvement plan. The improvement process is initiated by developing the current state mapping and evaluating the future state mapping. The improvement plans consist of identifying and sorting existing tools, developing a database system as a repository of the existing tools, and storage organization through labeling. The implementation of improvement plans results in the elimination of the buy-off process and reduction of the overall cycle time and lead time by 31.34% or 89 minutes, and 99.84% or 28,789 minutes respectively. Furthermore, there was a 51.4% reduction in the box purchases in 2022 resulting in a major cost saving. Therefore, the research findings are considered significant and valuable for the Toy Manufacturing Company by increasing the efficiency of tools utilization in the pack-out process.