Productivity Improvement by Reducing Material Waste in Corrugated Paperboard Process

Abstract

UNIPAKNILE is a member of INDEVCO Paper Containers, a division of the INDEVCO Group, established in 1996 and located in Cairo, Egypt. Operating corrugated packaging manufacturing and converting companies across the Middle East. The company specializes in supplying a wide range of industrial and agricultural corrugated packaging solutions, as well as delivery boxes. The project focuses on reducing material waste that reduces the profitability of the company, as well as raising cardboard sheet productivity and achieving the greatest possible production rate while maintaining the required quality level. The cardboard manufacturing process was investigated to detect the sources of the production problems. During the investigation, a significant amount of material waste related to warehouse and production process was observed. The project aims to reduce material waste from 377 tons per month to around 267 tons per month with a reduction of 29.1%, using industrial engineering techniques such as lean 5S. This reduction in waste will raise the company's productivity while also improving the material quality and thus the manufacturing process.