Waste Reduction in a Cooker’s Glass Processing Factory

Abstract

Union air Cooker’s Glass Processing Factory is specialized in manufacturing of different glass products such as cookers, ovens, televisions, heaters, fridges, and deep freezers glass faces. It is a part of Union air Group, which has been operational since 1995, and is recognized for its innovative and high-quality products such as air conditioners, washing machines, refrigerators, and cookers. The glass factory is located in Industrial zone, 6th of October, Giza, Egypt, the factory was established in 2017. The factory produces annually 768,000 square meters of glass products. The aim of this project is to identify the wasted glass material in all glass processing stations and analyze this data to propose suitable solution in order to minimize waste and improve productivity in the factory. The initial status of the factory is that it is highly inefficient and suffering huge losses that have not been reliably quantified prior to this project. This project focuses on implementing lean production techniques such as 5S, standard operation, maintenance routine checklist, employee training, and quality control to reduce the wasted material. The achieved result showed that the glass waste is reduced from 30% to 15%, with total saving per year of approximately 9 Million LE.