DEVELOPMENT OF CONTINUOUS IMPROVEMENT GUIDELINE FOR CIRCULAR WAREHOUSE OPERATIONS: A CASE STUDY OF PLASTIC PELLET PACKING IN THAILAND
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Abstract
This research aimed to analyze and explain operational problems in the plastic pellet packaging process in Thailand and to develop practical guidelines for continuous improvement system within a circular warehouse management framework. The study focused on reducing the management costs of large packaging bags and decreasing processing time that affects productivity during the packaging stage. A mixed-methods approach was employed in plastic pellet manufacturing company located in the Eastern Industrial Zone of Thailand. The research area covered warehouse packaging operations in plastic pellet manufacturing industry. The sample consisted of production and warehouse employees selected through purposive sampling. The research instruments included time-recording forms, interview protocols, field observations, and questionnaires. Qualitative data was first collected to examine current conditions and work processes through in-depth interviews. The interview data were summarized using content analysis, while participatory observations on production line were documented through field notes. Quantitative data were gathered using questionnaires that assessed operational efficiency before and after the improvement initiative. The study combined work process analysis with employee opinion surveys to evaluate effectiveness of implemented improvements. The findings indicated significant productivity enhancement. Time-related productivity improved by 19.33%, while the overall improvement rate increased by 18.50% following implementation of proposed practices. The results were presented through a project-based improvement framework that incorporated productivity indicators and measures of material recirculation capability. Overall operator satisfaction with improved process was rated at very high level. The study contributes by synthesizing practical principles that can be extended to other sub-processes within warehouse operations. It also provides new knowledge in the form of a daily work improvement model derived from process analysis and selection of operational steps that have greatest impact on productivity indicators and the effective reuse of circulating materials. The proposed operational guidelines offer a practical approach for continuous improvement and support development of sustainable circular warehouse management practices.
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