Production time loss reduction in an ice-cream factory

Abstract

Ice-cream’s demands are increasing every year. The factory needs improvement in order to support customers’ demands. From identifying the problem, it was found that the factory could not meet the customers’ demands because the ideal production volume was low. This type of volume is 90% of the maximum production volume. Because of long production time per cycle, the ideal volume is low and unable to meet customers’ demands. The main cause effects both production time and production volume is the production time and production volume is the production time loss. Therefore, this study is interested in production improvement. The objective of this study is to reduce the production time losses in the stick line that has the most serious demands. From studying, there are two main loss times in a production process. They are set up time and freezing time. First of all, should collect data, and analyse them by using why-why analysis in order to know the root causes. From the why-why analysis, it was shown there are a number of ineffective procedures in the set up process. These procedures spent a long time. In the freezing process, it uses an unsuitable freezing agent, which takes a long time not only in transferring heat but also getting the appropriate freezing point. After what, plan to improve the set up process and freezing process by applying ECRS technique. This technique is not only improves procedures but also develops helpful equipment. Then, analyse by economic evaluation. From this evaluation, it can conclude that the company should invest only in changeover project. After the implementation, the improved processes can reduce set up time from 6.90 hrs per production cycle to 2.43 hrs per production cycle or about 64.78% while the manufacturing cost can reduce from 148.75 Baht per liter to 123 Baht per liter or approximately 17.31% For that reason, ideal production volumes are increased about 5 times, which are not only can support this year’s demands but also the forecasting’s.