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.
