Research, Calculation, and Improvement of Productivity and Quality in the Production Process of Cosmetic Display Cabinets

The application of lean manufacturing principles, combined with a focus on continuous improvement, serves as a vital approach for industries to thrive in the face of global competition. As the population grows, the demand for technology has reached unprecedented levels, driving a steady increase in the production of existing models and the creation of new product designs. An efficient plant layout enhances resource utilization and facilitates the implementation of lean tools such as 5S, the seven wastes, Kanban, and Just-In-Time (JIT). These tools help reduce costs and improve product quality, delivering significant advantages to the organization. It also streamlines the process of applying Systematic Layout Planning (SLP) to create new layouts. The research addresses the challenges faced by the company in optimizing production efficiency and enhancing product quality to improve competitiveness. Systematic Layout Planning (SLP) and the DMAIC framework were employed to identify inefficiencies and implement improvements. Results indicate significantly reduced production defects and bottlenecks, enhancing workflow and cost savings. The new factory layout reduced material handling distances while improving maintenance checklists, workflow arrangements, and operational efficiency. This research provides actionable insights and practical solutions, offering substantial value to the company and serving as a model for similar industries seeking productivity and quality enhancements. The comparison layout design resulted in 2 alternative layouts that are better than the initial layout. The chosen layout design is Alternative 1 because it reduces transportation time and increases movement efficiency. In addition, the proposed approach is the DMAIC approach, and its tools are used to assess the impact of mistakes on the production process. As a result, this study will also conclude how the DMAIC approach can help the company reduce waste. Suggestions related to DMAIC tools and their implementation are also elaborated so the related company can evaluate its current process and strive for better improvement.