Optimizing Production Efficiency Through Improved Operator Workflows

Despite extensive literature on productivity optimization, a notable gap remains in practical approaches tailored to drum assembly operations, which face layout-specific constraints such as long distances between workstations and inconsistent pallet stacking that lead to inefficiencies. This study focuses on optimizing operator workflows to enhance production efficiency within the assembly area of drums production in a packaging industry. The plant currently operates four production lines, with the goal of expanding to five without increasing the number of operators. To address this, the A3 methodology, an approach grounded in the PDCA (Plan-Do-Check-Act) cycle, was applied. Through Gemba walks and data-driven observations, operator tasks were categorized into value-added and non-value-added activities. A Pareto analysis prioritized non-value-added tasks, identifying movements, interruptions, and loading activities as the primary contributors to inefficiencies. A fishbone diagram and root cause analysis were employed to understand underlying issues, leading to the development of targeted countermeasures. These included standardizing pallet stacking, optimizing component storage, implementing standard operating procedures, and enhancing maintenance practices. Countermeasures were selected based on their high impact and low implementation effort, resulting in improved operator productivity and enabling simultaneous operation of all five lines. The reduction in non-value-added activities also led to significant cost savings. This study demonstrates how integrating lean practices and ergonomic principles can improve operational performance and serve as a scalable model for broader manufacturing applications. This case contributes both theoretically and practically by demonstrating how structured, low-cost interventions, rather than digitalization alone, can optimize human-driven workflows and enhance productivity in industrial environments.