Optimization of Chemical Manufacturing Process Area

Abstract

“Industry X” does not have a detailed and effective plan for chemical weighing process which considers optimal number of operators and shifts necessary to accomplish the desired production. The products process flow has inefficiencies due to non value added task and the absence of standardization in this area. The material flow was analyzed using with a Kaizen to decrease the material time period which is 306 feet’s from since it leaves the warehouse until it is dispensed. A time measurement studies were performed in order to determine the best time standards for the process. To improve the weighing process, several layouts were analyzed to identify the most effective alternative to reduce the transportation distance in a 42%. Also to improve the documentation area it is proposed to document the required data in the System Application & Products (SAP) system and the electronic batch record with a logbook restructuration to reduce the documentation amount above 50%. Using the proposed layout and documentation alternatives which comply with the industry standards and the production forecast, a shift of 4 satisfy the demand. Key Terms - chemical weighing, dispensing process, Kaizen, SAP system.