Optimization of packaging operations for beer production line efficiency : case study packaging line 1, Nile breweries limited

Abstract

In light of the need for beer production plants to foster competitiveness in today‟s beer market, Nile Breweries Limited packaging beer line 1 factory efficiency dropped from 83.25% in January 2015 to 56.8% in January 2018 due to availability losses, performance losses and quality losses. Through optimization of packaging operations to improve line efficiency above 83.25%, by identifying bottlenecks, determining efficiency loss caused by bottlenecks and optimizing line 1 using lean manufacturing tools, a sample survey research design was carried out. Through observations, qualitative and quantitative data was collected to identify bottleneck machines using stop watch and data gathering worksheet. Data was analysed using fishbone method, graphs and tables. Depalletizer and palletizer machines were identified as bottleneck machines with efficiency drop from 135% V-profile efficiency to 109% and 120% respectively and general line efficiency loss of 18.8%, hence causing a total financial loss of USD 1,174,378.377 by January 2018. Through detailed implementation of unified theory for lean manufacturing tools, line balancing and adopting new preventive maintenance strategy, waste reduction measures are proposed in order to improve machine performance and factory efficiency above 89% and 83.25% respectively.