Reducing Waste from Delays in the Bag Manufacturing Process through Integrated Supply Chain Management and ECRS Principles
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Abstract
Delays embedded in fragmented supply chains generate significant lead-time waste in Thailand’s bag-manufacturing sector. This research aims to study the reduction of waste from delays in the bag production process through integrated supply chain management and the ECRS principles (Eliminate, Combine, Rearrange, Simplify), using a bag manufacturing factory in Bangkok as an in-depth case study. Data were gathered through participatory observation and in-depth interviews with ten key informants, complemented by a small group interview for a comprehensive process analysis. Analytical tools included IDEF0 process maps, the SIPOC (Supplier–Input–Process–Output–Customer) model, How-How analysis, and tree diagrams. The production process originally comprised 30 activities, five of which were classified as non-value-adding (NVA). The improvement initiative eliminated all NVA activities, reducing the process to 25. As a result, the average cycle time for production has decreased from 101.28 minutes to 40.25 minutes, and material-handling distance decreased from 87.8 metres to 85.8 metres. This study reveals that the integration of supply chain management with ECRS principles significantly reduces waste caused by production delays, ensures timely product delivery, and strengthens the competitiveness of the bag manufacturing industry and related sectors.
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