Application of ECRS Principles Combined with 5W1H Technique and Automatic Feeder System Design to Increase Production Rate of Profile F1 Sanding Machine

Abstract

This study aims to enhance production efficiency and eliminate bottlenecks in the Profile F1 sanding line production process. Preliminary analysis revealed that production rates were not meeting the targets due to the discontinuity of manual workpiece feeding, resulting in gaps between workpieces, machine idle time, and employee fatigue. A root cause analysis using Why-Why Analysis confirmed that reliance on manual labor for feeding without auxiliary equipment was the main cause of the problem To address this issue, industrial engineering methodologies were applied, specifically using the ECRS (Eliminate, Combine, Rearrange, Simplify) principles combined with the 5W1H technique to analyze and design an Automatic Feeder System to replace the manual handling process. The implementation of this system significantly improved the continuity of the process. Prior to the improvement, the average production rate was 1,084.0 pieces per hour; after the installation of the automatic feeder, the production rate increased to 1,605.8 pieces per hour, resulting in a 49% increase in production. This outcome successfully achieved the project objectives and sustainably eliminated the production line bottleneck.