Waste Reduction in a Corrugated Cardboard Factory

Abstract

Universal Unipack has two branches specialized in packaging industry. It manufactures corrugated cardboard and prints on it. It was established in 1981, at the second industrial zone at 10th of Ramadan city-Egypt, the other branch is located in the Sadat city. After investigating the corrugated cardboard production line, it was found that there are two main problems in the factory. First, there are a lot of scrap that comes out from the production line, the average for production in a month is 2495.2 tons which has 290 tons waste from the production process which is about 12%. Secondly, the layers of cardboard peel off easily because of bad starch that they use to glue the layers with each other. This project aims to reduce waste in a corrugated cardboard factory from 290 (tons per month), which will reduce the material waste by almost 14 % and save them 920,000 L.E by using lean six sigma and 5s methodology. The achieved results will be increase the productivity of the corrugated cardboard by reducing the waste in the production line.