International Journal of Engineering and Advanced Technology (IJEAT)

ISSN: 2249-8958 (Online), Volume-8 Issue-5C, May 2019

Productivity Improvement Of Corrugated

Carton Industry By Implementation Of
Continuous Improvement, 5s, Work Study, And
Muda Elimination: A Case Study Of Xyz Co.,
Ltd.
Piyachat Burawat
ABSTRACT--- The purpose of this study is to make corrugated carton industry, which is competitive in aspects
productivity better by means of 5S, work study, and Muda of price, product quality, time delivery, and customer
elimination in corrugated carton industry which was conducted satisfaction, cross-border business, electronic commerce
from November 2018 to March 2019 from a case study of XYZ
business, opening countries and trade zones in both the
Co., Ltd. The data were collected from managers and supervisors
and the problems were analyzed by brainstorming together with Eastern and Western countries, has become a stimulus for
cause and effect diagram. Crucial problems of production business needs to be adapted to keep up with the changing
occurred from human errors, i.e. production employees ignored business circumstances. This new knowledge-based
to check the availability of machines before operating the challenge requires effective management tools to assist the
machine, production employees neglected to prepare materials company to meet customer requirements. During the past
for next orders while machines operating, and warehouse
periods, the principles and theories of modern production
employees randomly checked the humidity before the storage of
corrugated sheet papers. Employees could be trained about and quality improvement have always been developed.
production process, machine operation, quality inspection, and According to high competition and rapid changing business
planning process. The production process could be changed from conditions as well as quality and waste problem in both
operating machine without checking machine availability and corrugated carton production and storage process, this study
removing material remains in the machine to check availability contributes present investigations by examining the
and removing materials remains in the machine before operating
productivity improvement by applying 5S, work study, and
new purchasing order. The output was then increased from 2,000
to 2,300 ton per month, accounting for 15.00 percent of Muda elimination principles to diminish the work process
improvement. The defect was reduced from 160 to 140 pieces per and rectify the working method, while setting up a new
month, accounting for 12.50 percent of improvement. Regarding working area according to the principle of 5S to allow
the storage process, it could be changed from random check of employees in the warehouse to work more easily. In
humidity to check of humidity every time. The messy in addition, this study struggles to decrease quality problems,
warehouse had caused mixing of wet or damp raw materials with
wastes, delays and the number of defects that affect the cost
good quality raw materials. Once it was improved by cleaning,
classifying materials, products and areas with sign boards, the of the company by waste elimination principles which
results showed that the materials and products were easier to find enable the company to be more competitive in the industry.
and product quality was increased. Company launches 5S policy
and doing 5S activities continuously twice a month. The findings II. LITERATURE REVIEW
presented that the number of employees who neglected to comply
with the organizational regulations was reduced from 6 to 2 A. Productivity
persons, accounting for 66.67 percent of improvement. A comprehensive explanation of productivity is the
Keywords: Muda elimination, Productivity, 5S, Work study association between the output produced by a service or
production process and the input supplied to generate this
I. INTRODUCTION
output [1]. Consequently, productivity is described as the
Recently, productivity improvement is one of the most effective consume of resources, e.g. labor, material, land,
important to business operation and management, which can information, capital, energy; in the manufacturing of diverse
be applied in both manufacturing and service industry. Due products and services [2]. In addition, higher productivity
to ferocious competition in all businesses, particularly in means accomplishing more with the same amount of
resources or achieving higher outputs in terms of volume
and quality with the same input [3]. Moreover, productivity
is viewed in terms of efficiency and effectiveness of work
Manuscript published on 30 May 2019.
* Correspondence Author (s) [2].
Piyachat Burawat, Faculty of Business Administration, Rajamangala
University of Technology Thanyaburi / Pathumthani, Thailand.

© The Authors. Published by Blue Eyes Intelligence Engineering and

Sciences Publication (BEIESP). This is an open access article under the
CC-BY-NC-ND license http://creativecommons.org/licenses/by-nc-nd/4.0/

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DOI:10.35940/ijeat.E1026.0585C19 Blue Eyes Intelligence Engineering
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 International Conference on Recents Advancements in Engineering and Technology (ICRAET-18) |15th and 16th
March 2019|Siddhartha Institute of Technology & Sciences, Telangana, India.

Since globalization has an effect on continuous workplace, removal of inferior results related to lack of
competition in all business industry, many researchers have successes and breaks, and development of workplace both
argued that the definition of productivity as the ratio safety and quality [13]. The notion of the 5S has its origin in
between output and input as well as the terms of efficiency Japan, developed by Osada [14] in the early 1980s [15]. The
and effectiveness resulting from the use of the said resources name 5S is the abbreviation of five Japanese words
is narrow and inappropriate for measuring the success of the including Seri, Seiton, Seiso, Seiketsu, and Shitsuke.
current business [4, 5]. Thus, modern notion of productivity First, Seri (sort) is aimed to sort, organize the workplace,
includes consideration of social and ecological costs, ability and get rid of superfluous materials. Through the
to create value for customers and stakeholders in the supply appropriate classifying, it can identify the materials,
chain, ability to meet customers’ requirements that change equipment, tools and inevitable information for
over time, survival in high competition, and agility and comprehension the tasks. Sorting or classifying removes the
speed in adapting to meet customer needs [4, 5]. excess of both raw materials and materials, defective
products, and damaged tools and equipment. It assists to
B. Continuous Improvement
keep the polished and tidy workplace and raises the
Continuous improvement can be viewed as several effectiveness of exploring and acquiring things, cutting the
aspects. First, continuous improvement is as much a period of managing the production. Second, Seiton (set in
philosophy as a set of particular techniques and quality order) aims to visualize the workplace and place for
instruments. Thus, it would be seemed to be specifically everything (e.g. painting the floor assists to determine the
essential for executives to have an attention regarding areas of storage of each raw material, material or transport
procedure emphasizing on the appropriate method of trails; sketching the appearances of equipment and tools
performing things. Second, continuous improvement can be helps it possible for the rapid positioning aside them on the
seen as generic characteristics which focus on the value of constant areas; colored labels allow to determine the raw
making continuous incremental changes [6]. Users materials, materials, surplus parts or official papers etc.). It
emphasize on creating minor changes, amending should carry out the separation of items or objects and
procedures, and finally generating a substantial progressive indicate the areas of their keeping. Third, Seiso (shine) aims
result [6, 7]. While each trivial alter may not have a to clean and remove wastes or dust. Ordinary cleaning
quantifiable impact, the progressive result can be completely allows to determine and to get rid of origins of disordering
profound. Third, continuous improvement is viewed as and to perpetuate the clean workspaces. Throughout the time
improving method for both products and processes which of cleaning, it checks the cleanness of workplace, floor and
involve employees from all positions and all departments in machine, conciseness of equipment, neatness of pipes, lines,
the company [8]. The objective is to eliminate wasteful origins of light, present data, clarity and comprehensibility
practices [9] and achieve lean production [10]. Employees of provided information, etc. Indispensable is the looking
persistently chip away the fatty tissues of firm and establish after of and preservation of individual neat of the employee.
lean manufacturing procedures [9]. Finally, continuous Next, Seiketsu (standardize) aims to be indicated area for
improvement is a category of meditation approach that objects or items, consistent regulations of company,
discloses its profundity only through continual reiteration preservation and maintaining cleanness. Worked out and
and modification [11]. applied guidelines in the form of instructions and procedures
The Deming’s quality cycle or PDCA-cycle is used to allow to maintain the order on the workspaces. Guidelines
coordinate continuous improvement efforts. The should be extremely communicative, explicit and
accomplishment of one cycle continues with the beginning uncomplicated to comprehend. In respect of this period of
of the next. A PDCA-cycle comprises four sequential phases arrangements and getting better, it should involve all
or steps. First, plan step is an investigation of what requires participants of the procedure on the specified workspace; it
to be made better by taking into consideration areas that means direct employees. The group realizes the best
possess chances for alteration, e.g. determination on what specificity of its own activities, and method of elaboration
should be modified. Second, do step is an application of the and after that, usage provides them chance of
alternations that are determined on in the plan phase. Third, comprehending the essence and each manner of the
check phase is a control and measurement of products and operation. In the purpose of convincing all the effortless
processes in accordance to modifications made in preceding access, compulsory guidelines should be found in
phases and in accordance to policies, desired results and unchanging and perceptible areas. Finally, Shitsuke (sustain)
products requirements. Lastly, act step is a reaction or an aims to be automatic realization of the above-mentioned
adoption to the alternations or handling the PDCA-cycle rules [16]. Applying the notion of the 5S will desire from
through again, maintaining continuous improvement [12]. employees the massive self-discipline related to applying
C. 5S Practices and complying with the rules of regularity in classifying and
cleaning. It brings about expanding the awareness of
The 5S practice embarks on each programme of
employees, and declining the quantity of defective products
improvement. It is the technique for assisting the
and systems, advances in the internal transmission, and
investigation of processes managing on the place of work.
through this to enhancement in the human relations.
The 5S is the approach of generation and perpetuating
effectively managed, clean, highly successful and excessive
quality place of work. Its consequence is the productive
company of the place of work, depletion of environment of

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DOI:10.35940/ijeat.E1026.0585C19 Blue Eyes Intelligence Engineering
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179 © Copyright: All rights reserved.
 International Journal of Engineering and Advanced Technology (IJEAT)
ISSN: 2249-8958 (Online), Volume-8 Issue-5C, May 2019

D. Work Study the existence of these wastes. The list of wastes can also
Work study is an essential management technique to indicate possible goals for continuous improvement
accomplish superior productivity. It is associated with endeavors.
individual work, process of performing tasks and standard of
performance. The existence of any company is based on III. RESEARCH METHODOLOGY
utilization of the latest technology and effective production The purpose of this examination is to enhance
processes. To get better effectiveness of production, it productivity in corrugated carton industry. The study was
requires productive mobilization of factory, tools, conducted from November 2018 to March 2019 from XYZ
equipment and employees. This can be accomplished by Co., Ltd. The data were collected from the managers and
implementing work study which studies methods and supervisors and the problems were analyzed by
measures the performance. It separates tasks into diminutive brainstorming and cause and effect diagram. The current
components, learns it, and repositions it to receive the productivity is measured by the ratio between current output
regular or higher effectiveness at diminished cost. divided by current input. After measuring current
Work study was defined by International Labor productivity, the analyzed and improved processes were
Organization as the procedure of method study and work developed by means of 5S, work study, and Muda
measurement employed to endorse the excellent conceivable elimination. Next, the productivity after improvement was
utilization of employee and material resources in managing measured by the ratio between output after improvement,
a determined activity. It is also a supervision service divided by input after improvement. Meanwhile,
dependent on method study and work measurement applied productivity growth was calculated by the ratio between the
in assessment of individual work resulting in examination of difference of productivity after improvement and current
all the resources that affect effectiveness and economy of productivity, divided by current productivity.
situation in order to bring about development. Moreover, Table 1. Analyzing Wastes and Problems
International Labor Organization asserts that work study is Wastes/ Details Targeted
aimed to decrease cost either by designing the work for Problems
extreme productivity or by developing productivity in Machine idle time Employees stopped Reduce the machine
current job through improvement in existing processes by machine 1-2 hours to idle time from 1-2
prepare materials and hours to 15-30
decreasing inefficient and squandered time [17]. equipment while minutes.
E. Muda Elimination changing new Increase output more
purchasing order than 10 percent
The Muda is defined as losses and wastes which refer to Defect work Material of preceding Reduce defect work
any activity that does not increase any worth to the pieces order remained in the pieces from 160 pieces
purchaser or that the purchaser is not hearty to expend for. machine while per month to less than
Waste emerges in whole process and in company. No operating machine for 145 pieces per month
matter how effective or efficient a process may be, some new purchasing order
Take long time to Mixing among wet, Improved by 5S
degree of waste is normally displayed. Ohno, often
find quality roll of damp, and quality roll principles, leading to
mentioned to as the father of the Toyota Production System corrugated paper of corrugated paper ease to find and reduce
[18], determined seven forms of waste that occur in a sorting and classifying
process including: 1) inventory refers to the number of items Higher defects Wet and damp rolls time
of work at each activity step. Inventory waste is items due to low quality interlaced or Removing wet and
beyond minimal quantities and an idle resource which takes of raw materials overlapped to other damp roll to other
rolls of corrugated place leading to
up floor space and adds to cost such as superfluous raw
paper reduced defect of raw
material, work in process, and finished products, and materials
redundant operating suppliers. 2) Overproduction involves Employees 6 employees ignored Reduce number of
excessive use of manufacturing resources or output that ignored to comply to comply with rules employees who
exceeds the customer expectation or was produced early rules and and regulations neglected rules and
(before it is demanded). 3) Waiting time refers to the time regulations regulations from 6 to 3
person.
spent waiting between activities, queues, and idle time,
which requires space and adds no value. 4) Unnecessary 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑂𝑢𝑡𝑝𝑢𝑡
transporting refers to movement between activities which 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 = (1)
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐼𝑛𝑝𝑢𝑡
increases handling and work in process such as moving
materials between plants or between work centers and 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑎𝑓𝑡𝑒𝑟 𝐼𝑚𝑝𝑟𝑜𝑣𝑒𝑚𝑒𝑛𝑡 =
handling more than once. 5) Overprocessing refers to 𝑂𝑢𝑡𝑝𝑢𝑡 𝑎𝑓𝑡𝑒𝑟 𝑖𝑚𝑝𝑟𝑜𝑣𝑒𝑚𝑒𝑛𝑡
(2)
unnecessary production steps and scraps such as work 𝐼𝑛𝑝𝑢𝑡 𝑎𝑓𝑡𝑒𝑟 𝑖𝑚𝑝𝑟𝑜𝑣𝑒𝑛𝑡

performed higher than customer required which requires

higher resources than actual need. 6) Inefficient work 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝐺𝑟𝑜𝑤𝑡ℎ =
(𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑎𝑓𝑡𝑒𝑟 𝐼𝑚𝑝𝑟𝑜𝑣𝑒𝑚𝑒𝑛𝑡−𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦)
methods reduce productivity and increase work in process (3)
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦
inventory such as excess movement of equipment or
employee that increases no value. 7) defective products
require rework costs, returns, warranty claims, scraps, and
possible lost sales due to customer dissatisfaction [12]. The
indication that specifies the possibility of improvement is

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DOI:10.35940/ijeat.E1026.0585C19 Blue Eyes Intelligence Engineering
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 International Conference on Recents Advancements in Engineering and Technology (ICRAET-18) |15th and 16th
March 2019|Siddhartha Institute of Technology & Sciences, Telangana, India.

IV. RESULTS AND FINDINGS mixing among wet, damp, and quality rolls of corrugated
paper resulted in moisture penetrated to quality roll of paper,
A. Results from brainstorming and cause and effect
causing defect raw materials. Figure 2 shows the warehouse
diagram
area before improvement while figure 3 presents warehouse
Based on the participation and observation study together after improvement.
with brainstorming with managers, supervisors, and relevant
employees, as shown in the figure 1, and referring to the
results, it was found that crucial problems of corrugated
carton production occurred from human errors which
include production employees who ignored to check the
availability of machines before operating the machine, and
production employees who ignored to prepare material for
next order while machines operating, and warehouse
employees who randomly checked the humidity of
warehouse area before storage corrugated sheet papers.

Fig.2. Warehouse Area Before Improvement

Fig.1. Results from Brainstorming and Cause and

Effect Diagram
B. Results of improvement in production process Fig.3. Improvement Warehouse Using 5S
Based on work study, the results presented that there are
many defect work pieces in cutting process. Considering the Results of improvement in warehouse area using 5S
production process, employees could be trained about practice are as followed. First, Seri (sort) was implemented
production process, machine operation, quality inspection, by sorting quality, defect, wet and damp rolls of corrugated
and planning process. The production process could be paper. Then, defect, wet, and damp rolls of corrugated paper
changed from operating machine without checking machine were moved or eliminated from the warehouse area. Second,
availability and removing materials remains in the machine Seiton (set in order) was implemented by keeping each type
to check availability and removing materials remains in the roll of corrugated paper according to the frequent and
machine before operating new purchasing order. In addition, important usage. Written and hanged labels were provided
defect work pieces occur when changing mold for cutting to reduce errors and ease to utilize. Third, Seiso (shine) was
process. Thus, new employees need to be well trained before implemented by regular maintaining cleanliness both
starting to work. Moreover, employees disregarded to check working area and machine, leading to no crumbs that cause
product schedule and neglected to prepare material, cutting problems in the speed and safety of the machine as well as
mold, and tools while the machine was operating which well sceneries in the workplace. Next, Seiketsu (standardize)
results in wastes in production department as well as stop of was implemented by setting correct work instruction,
machines. Work instruction must include preparing training for correct work method, and seriously complying
materials and setting up tools and equipment while machine rules and regulations. Finally, Shitsuke (sustain) was
is operating in order to avoid and reduce machine idle time implemented by maintaining the above improved systems,
while changing to produce new model. In addition, all communicating and announcing to all employees that 5S is
employees must comply with company rules seriously. After essential and requires collaboration from employees and the
improvement, the corrugated carton output was then compact self-discipline related to applying and complying
increased from 2,000 tons per month to 2,300 tons per with the regulations of generality in sorting and cleaning. In
month, accounting for 15.00 percent of improvement. The addition, the company launches 5S activities at least twice a
production defect was reduced from 160 pieces per month to month, which all employees comply to participate.
140 pieces per month, accounting for 12.50 percent of
improvement.
C. Results of improvement in warehouse area
After work study, the results presented that rolls of
corrugated paper were located in wrong position, messy, and

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 International Journal of Engineering and Advanced Technology (IJEAT)
ISSN: 2249-8958 (Online), Volume-8 Issue-5C, May 2019

Regarding the storage process, once it was improved by continuous development. Muda elimination is one of the
sorting, cleaning, classifying materials, products and areas options to reduce non value-added activity (wastes) and
with sign boards, the results showed that the materials and improve operational efficiency of the organization. The
products were easier to find and product quality was efficient implementation of 5S technique leads to
increased. The findings presented that the number of improvement in environmental performance and thus
employees who neglected to comply with the regulations of primarily related to reduction of wastes in manufacturing. It
the company was reduced from 6 persons to 2 persons, promotes neatness in storage of raw materials and finished
accounting for 66.67 percent of improvement. products, reduction in accident, and increase of awareness
and moral of employees [19]. Regarding work study, both
V. DISCUSSIONS AND CONCLUSION method and time study are necessary to be analyzed at the
The purpose of this study is to reduce waste and improve same time as changing method leads to reducing time.
productivity in corrugated carton industry. Brain storming Regarding method improvement, it is unnecessary to change
and cause and effect were used to identify root causes of or invent new machine or equipment as method can be
wastes, bottleneck, and quality problems. Referring to the improved by study motion and process, eliminated
results, it was found that crucial problems of corrugated unnecessary motion and movements, and rearranged or
carton production occurred from human error. Human error excised superfluous processes.
can occur from the two causes, i.e. not knowing the The findings demonstrated that 5S, work study, and Muda
rules/procedures of work, and knowing but deciding to elimination can be viewed as an efficient method that can
ignore them. New employees may be doing wrong due to reduce waste and improve business performance which can
not knowing the rules/procedures of work or be implemented in any industry as well as any size of
misunderstanding them, and the error can be eliminated by company. It can be considered as the promotion of the
providing well training before working and coaching while improvement techniques amongst the employees and as a
doing their job. On the other hand, current employees may training approach for the employees. The findings
be ignoring rules and regulations due to weak enforcement, demonstrated, nevertheless, that there are hurdles in the
considered not important. Communication is essential to successful utilization of the improvement techniques for any
solve misunderstanding problem, both top-down and improvement goal. The most crucial obstacles recognized
bottom-up communication. Management needs to place are connected to depletion of communication, gap between
importance on communication and benefits of obeying work the executive and shop floor operators and also the
instruction, rules and regulations, while focusing on 5S insufficiency of training and awareness of this activity
activities and the advantages to be derived, e.g. higher amongst the employees. Therefore, the full advantages of
productivity and income, fewer losses, wastes and working the improvement techniques cannot be knowledgeable in the
accidents. Meanwhile, employees need to transmit obstacles business sector as long as all the drawbacks related with
of complying which require to be supported from application of the improvement techniques are recognized,
management. Continuous improvement is known as Kaizen completely comprehended and tackled. Ceaseless evaluation
in Japanese. The implementation of the Kaizen notions in all levels of firms is one major driver to change the
assumes a ceaseless communication both vertical improvement culture of the company. This evaluation
communication between the executives and the workers and should be emphasized on the progress and improvement of
horizontal communication between the workers on the same quantity and quality of products, level of morale and
hierarchical level. The application of the Kaizen principles satisfaction of employee, level of quantity and quality of
relates to no crucial cost, but only increased observation to communication, financial performance, and customer
details and empirical methods to do things superior and satisfaction.
extremely effectively. The directly productive employees
are particularly encouraged so that they can suggest and VI. RECOMMENDATIONS
make improvements [19]. With a detailed analysis, the There are several recommendations as followed:
results have remarked that, even in the spaces where no 1) Japanese management and Toyota Production System
improvements are required such as warehouse area, there is techniques require a top-down technique that comes to be
still a lot of probability to get better. A well management of part of the corporate fabric. Teaching Toyota Production
human resources in the company is one of the strategic System techniques cannot take place in a classroom or
purposes of the firm which should be obviously described through seminars, but where the productions actually take
and admitted by all members. The continuous improvement place. To be successful, all employees must be completely
concepts are the resistance structure that should be built on, conscious of the diverse forms that waste can take and be
so that we can obtain to a sustained and step by step persistently watchful of any chances to attack and get rid of
improvement of the organizational performance. Difficult these wastes. Senior managers must normally walk through
situations should not be linked to employees because laying the productions, keeping an eye on the activities, asking
the blame on employees does not find the answer to the inquiries, and expressing their dedication to the process. Too
problem. Problem solving should use feed-back techniques. often, firms treat these processes as programs that can be
The results demonstrated that the implementation of 5S, began and ended as required.
work study, and Muda elimination techniques can be applied
in small scale industry. These techniques involve with
Toyota Production System which emphasizes on the active
participation of all employee categories, aiming to small but
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182 © Copyright: All rights reserved.
 International Conference on Recents Advancements in Engineering and Technology (ICRAET-18) |15th and 16th
March 2019|Siddhartha Institute of Technology & Sciences, Telangana, India.

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technologies, machines, and innovations, which require high
level of investment, a business needs to calculate break AUTHORS PROFILE
event point and payback period before deciding to invest in Dr. B. Piyachat received her bachelor’s degree of
training course for novel equipment utilization. production engineering from King Mongkut’s University
of Technology Thonburi, master degree of business
administration from Mahanakorn University of
VII. ACKNOWLEDGMENT Technology, and Ph.D degree in Management from
The author would like to demonstrate gratitude to all Rajamangala University of Technology Thanyaburi,
Thailand. She is currently working as Assistant Professor in the Faculty of
participants who gave priceless information, including the Business Administration, Rajamangala University of Technology
XYZ Co., Ltd., for the consents that authorized the author to Thanyaburi (RMUTT), Thailand. She has 10 years of working experience
successfully perform this study. in manufacturing industry and 5 years of teaching experience in industrial
management field.
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DOI:10.35940/ijeat.E1026.0585C19 Blue Eyes Intelligence Engineering
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