Reducing Cycle Time in Nivea Deodorant Production Line

Abstract

Scitra Contract Production factory has been specializing in personal and home care in UAE since 1976. Since 2016, the Egyptian branch has been located in the industrial zone in 6th October City. Furthermore, the plant has swiftly gained a reputation as one of the finest quality producers, which assists other companies in raising their productivity. Scitra specializes in personal care and home care products from firms such as Nivea, Rexona, Tide, Dove and Vanish. After investigating the whole production process of Nivea Deodorant product, it was found out that the washing process of the mixers used to take four and a half hours to be washed, rinsed and sterilized. Furthermore, the pre-weighing process takes around two hours to prepare and weigh all the needed materials to be mixed. Additionally, the changeover time is a considerable delay resulting in a full stoppage for the whole production line for five hours long to change from a size to another. Finally, there is a frequent stoppage occurred in Nivea Deodorant production line because of lack of knowledge of the workers in operating the Cap Screwing machine. The project aims to reduce the time waste of the aforementioned problems which will reduce the cycle time of Nivea Deodorant production process, and the results obtained demonstrated a 15% reduction in cycle time. This is achieved by using industrial engineering techniques such as Operation Analysis, DMAIC, 5S, Value Stream Mapping (VSM), Correlation and Regression Analysis, and Single Minute Exchange of Dies (SMED).