Enhancing Efficiency in Extract Adjustment for Packaged Goods Using Kaizen Principles

This study aims to provide recommendations for reducing production downtime in the extraction process. Tannin extraction has been identified as a major cause of high downtime. The research involves testing improved work methods by examining the impact of machine settings on the extraction process, evaluating how raw materials influence extraction outcomes, and using the PDCA method (Plan, Do, Check, Action) for these assessments. This study has been conducted at a company that produces 350 ml bottled tea beverages and frequently experiences production downtime, negatively affecting profit margins, worker efficiency, inventory planning, and production cycles. The research suggests alternative solutions to enhance production methods, applying the Kaizen approach, which focuses on continuous improvement. The study findings reveal that machine settings significantly affect the agitation process for tea extracts, with optimal RPM settings ranging from 107.3 to 119.8 RPM and an agitation time of 25 minutes, followed by 10 minutes of standing time. The research also indicates that the storage age of raw materials influences the levels of extracted tannins, affecting the quality of the final product.