Minimization of Root Causes of Declining Productivity in a Manufacturing Company: A Case Study of Jocalis Company

Abstract

This presents a comprehensive methodology employed to identify and address declining productivity issues within the JOCALIS Aluminium Roofing Sheet Manufacturing Company Limited, situated in Onitsha, Nigeria. The study encompasses various manufacturing divisions, with a primary focus on aluminium roofing sheet production of three lines involve in production of red, black, and milk colour coated roofing sheet. The research aims to uncover the root causes of defects in the manufacturing process and develop effective strategies for improvement. Key methods include data collection through interviews, company records, library research, and internet sources, followed by data analysis and root cause identification. From the result obtained, the average availability of critical machine like the roller machine after root cause analysis is increased by 10.62%. Also, the average MTBF (mean time between failure) of the critical machine after root cause analysis is increased by 13.66% and MTTR (mean time to repair) is decreased to 46.42% respectively. The applications and general impact of this study includes enhancing machine availability, reducing downtime, increasing efficiency, optimizing maintenance practices, implementing preventive maintenance schedules, improving equipment diagnostics, and prioritizing root cause analysis to reduce breakdowns.