Enhancing Production Efficiency in a Modern Paint Industry

Abstract

Al-Masreya for Modern Paints (Anjo) established in 2019, is located in 10th of Ramadan City Egypt. The factory is specialized in producing a variety of paint products, including Walls Putty, Plastic Paints, Glue, and Sealers, aiming to provide competitive products in the Egyptian market. Most of their production includes Interior Putty, Exterior Putty, and Crack Fillers. After investigating the production processes, several issues were identified. First, the Crack Fillers product consumes a significant amount of time during the packaging stage, taking up to four hours per batch, causing delays and wasted time. Second, for the Interior Putty product, the production line faces several issues that cause time waste and delays. 70% of batches require modifications due to the lack of a standardized method, which further adds time and effort. Finally, starting from batch number 2, there is a waste of time due to delays in the raw material transfer process, affecting overall productivity. The project aims to reduce time waste in the production process by using industrial engineering techniques. To address specific issues, several improvements were planned. First, to reduce the long filling time in crack filler putty, additional scales were added to the production line to speed up the process. Second, SMED was applied to minimize machine idle time in the interior putty production. Lastly, Standard Operating Procedures (SOP) were implemented to reduce modification time in the interior putty production. This project led to significant improvements in the production processes of Interior Putty and Crack Filler. By applying industrial engineering techniques such as SMED, SOPs, and Line Balancing, machine idle time was reduced, modification rates were lowered, and weighing operations became more efficient. As a result, daily production capacity increased by 50%, raising the number of batches from two to three per day, while monthly overtime costs were reduced by 12,536 L.E. Overall, these improvements generated a monthly profit increase of 344,360 L.E, contributing to higher productivity, better resource utilization, and measurable financial gains.