5th Computational Methods and Ocean Technology (COTech 2026)

Improving Production Environment Through Lean Manufac￾turing in the Manufacturing Of Plastic Panels: The Case Of HK Business Group

Not scheduled

20m

KE E-102 (University of Stavanger, Norway)

Paper Contribution Smart Operations and Maintenanc

Speaker

Bikila Worku (Wallaga University)

Description

Abstract
This study investigates the implementation and impact of the 5S methodology on operational efficiency in the plastic panel production line of HK Business Group, located in Addis Ababa, Ethiopia. The research was motivated by challenges such as poor workplace organization, high defect rates, excessive waste, long lead times, and workplace safety concerns. A mixed-methods approach involving observation, interviews and document review was employed. Data collected before and after 5S implementation were compared to evaluate improvements in performance. The results showed that setup lead time decreased from 50 to 20 minutes (60%), defect rates were reduced by
more than 50%, scrap generation decreased from 82–200 kg to 80–90 kg per shift, and tool-searching time was reduced from about 5 minutes to less than 1 minute. Workplace safety and inventory management also improved, eliminating customer complaints related to product damage. The study concludes that 5S is a practical, low-cost, and effective tool for improving productivity, quality, safety, and workplace discipline, and can serve as a foundation for lean manufacturing implementation in Ethiopian industries.
Keywords: Lean manufacturing, operational efficiency, 5S methodology, Workplace organization, Plastic panel production