Optimization of productive processes: case study on Italian kitchen manufacturer packaging line

The enhancement of production processes represents a crucial factor in enabling global competitiveness, particularly in light of the challenges posed by fluctuating demand, operational uncertainties, and the ripple effects inherent to interconnected supply chains. This paper presents an examination of the optimization of a furniture packaging line within a large kitchen manufacturing company. The study highlights the need to achieve a balance between efficiency and flexibility, while addressing inherent factors of workspace, operator ergonomics and productivity. A case study is conducted for the purpose of collecting and analyzing data in order to identify inefficiencies in the current packaging workflow, with a particular focus on box handling and operator activities. It is discovered that significant inefficiencies exist in the excessive distance that operators have to travel in order to retrieve boxes and in the absence of a systematic approach to match box dimensions with furniture units. In order to address these issues, the research proposes the implementation of a mobile rack system. This solution optimizes the utilization of space, reduces the distance covered by operators, and enhances the efficiency of the line.