Abstract

This study examines the transition from traditional paperwork to a paperless manufacturing system in a plastic company, aiming to improve efficiency, reduce waste, and enhance production performance. Utilizing the DMAIC methodology (Define, Measure, Analyze, Improve, Control), the study focuses on minimizing manual paperwork time and optimizing resource management through automation of order handling and production scheduling. During the Measure phase, data showed the company uses about 5,700 papers per month, leading to production delays of 21.43 minutes per day and costing $4,310 per order. Analysis revealed that manual data entry and document transfers were the main causes of delays and errors.

The Improve phase implemented electronic data capture (EDC), workflow automation, and integrated systems, which reduced cycle time by 25% and manpower by 52% in pilot projects. The control phase introduced key performance indicators (KPIs) and real-time dashboards, alongside regular audits and a continuous improvement framework, to monitor and sustain the system’s success. The results indicate that adopting a paperless system could save the company 21.43 minutes of production time, $4,310 per order, and 285 papers daily, leading to significant improvements in operational efficiency and environmental sustainability.