Process Improvement Methodology: A Research Study of Process Improvement of Peppermint Tailoring via the Use of Operations Research
DOI:
https://doi.org/10.48017/dj.v11i3.3934Keywords:
Low-volume manufacturing, production efficiency, industrial engineering, facility layout, operations research, time-and-motion study, simulation modeling, task allocation, process improvement, ProModelAbstract
Low-volume manufacturing presents distinct operational challenges, including inefficiencies and production delays that can hinder productivity and limit output. This study investigates the manufacturing process of Peppermint Tailoring, a company engaged in low-volume T-shirt production, to identify and address inefficiencies using operations research and industrial engineering tools. Despite the prevalence of low-volume enterprises, literature addressing tailored process improvement strategies for such contexts remains limited. The research adopted a descriptive quantitative design, integrated with a case study approach. Key methodologies included time-and-motion studies, Fishbone Diagrams, and discrete-event simulation via ProModel. Data collection focused on measuring standard and actual task times to calculate production efficiency and assess resource utilization. Two alternative facility layouts were proposed and evaluated through simulation modeling. The initial production efficiency of Peppermint Tailoring was recorded at 73.08%. Following the implementation of the first proposed layout, efficiency rose significantly to 89.23%, while the second alternative achieved an 84.62% efficiency rate. The improvements were primarily attributed to strategic reallocation of worker tasks and redesigning the facility layout, which led to reduced idle time and enhanced workflow. Simulation outputs confirmed increased utilization rates and shortened task completion times. The study concludes that suboptimal facility arrangements and task allocations were the main contributors to production inefficiencies. The implemented interventions resulted in substantial improvements, validating the applicability of operations research and industrial engineering techniques in low-volume settings. The researchers recommend continuous monitoring, iterative facility layout evaluation, and worker-centered process enhancements to maintain and further improve operational efficiency.
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