Improving the Packaging Process of a Textile Company with Lean Production, Time Study and REBA Analysis

Abstract

Today, companies have to use their resources in the most effective and efficient way in order to effectively meet the increasing competition and changing demands of the customers. Among prominent methods, especially in production, are lean manufacturing techniques, time studies, and ergonomic assessments, alongside being frequently encountered methods. Within the scope of this study, value stream mapping (VSM), time study, and Rapid Entire Body Assessment (REBA) methods were used in order to reach the desired daily shipment amounts using the resources efficiently in the packaging area of the Boyar Kimya textile company, Gaziantep. Firstly, the standard time of the operations was determined by the time study method. The time study method was carried out with the ProTimeEstimation program. Afterwards, the most produced product was selected, the value-adding (VA) and non- value-adding (NVA) operations in the packaging department were determined in detail, and the future state map was created by finding methods to reduce or eliminate NVA operations. The ergonomic evaluation of the working performance of the operators in the packaging department was made with the REBA method. As a result of each method, it has been observed that with the proposed improvements the daily shipment increased dramatically, and the risk levels of the operators decreased.

Keywords

• Packaging process
• yarn bobbin
• time study
• value stream mapping
• REBA.

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