Improving the Efficiency of Plastic Cap Production Processes and In-Plant Material Handling for Beverage Plastic Caps (Tea Products): A Case Study of a Beverage Cap Manufacturing Company in Pathum Thani Province
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Abstract
This research aims to enhance the efficiency of the production process and in-plant material handling in a plastic cap manufacturing facility for tea beverage products. The study is conducted as a case study of a factory located in Pathum Thani Province, Thailand, which has experienced a relatively high defect rate in its production process. This situation is consistent with findings in the plastic packaging industry, which identify production and material handling waste as major contributors to hidden manufacturing costs. The research adopts a quantitative approach combined with action research in an industrial setting. The study applies the seven quality control (7 QC) tools, including check sheets, control charts, and fishbone diagrams, which are widely recognized for systematic root cause analysis of quality-related problems.
A before–after comparative analysis was conducted using key performance indicators (KPIs), namely defect rate, production cycle time, and material handling efficiency. The results indicate that the overall defect rate decreased from 0.1078% to 0.0798% following continuous improvement implementation over three consecutive quarters. These findings are consistent with Lean Manufacturing principles, which emphasize the elimination of non–value-added activities and the enhancement of overall operational efficiency. The results of this study suggest that the proposed approach can serve as a practical process improvement framework for plastic packaging manufacturing and other industries with similar production and material handling characteristics.
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