Abstract

Plastic bottle caps play a crucial role in sealing and preserving the contents of beverage containers, ensuring freshness and preventing leakage. This paper aims to optimize manufacturing processes at Plastic Bottle Caps Manufacturing Company to meet production objectives. Challenges include meeting daily demand quotas, boosting productivity, and refining layout processes of secondary processes by eliminating delays and downtime, employing tools like Time and Motion study, ProModel simulation, and DMAIC techniques. Ishikawa diagrams identify root causes and concentrate on the 6M's: Method, Machine, Manpower, Measurement, Material, and Money, while Pareto diagrams prioritize areas for improvement to alleviate bottlenecks. Proposing a U-shaped sequential layout enhances quality checking procedures, weighing processes, and increases worker productivity through reduced manpower allocation, machine monitoring, and improvement. It results in a 3.14-minute reduction in production time, eliminating 17.60 meters of unnecessary travel and reducing delay and waste time by 17.82%, surpassing the study's 4% improvement objective with a 15% allowance factor. Production increases to 33 cycles, yielding approximately 33,000 caps per day, representing an 18.18% productivity rate increase from 27 cycles. These improvements surpass the study's goals, meeting the daily quota and increasing productivity by 10%. The study recommends further modern approaches and methodologies to sustain effectiveness.