Course Title: Industrial Production Engineering & Waste Management – Flexible Packaging Industries

     

    Course Duration:

    • Total Duration: 2 Days

    • Daily Duration: 6 hours per day

    • Format: PowerPoint lectures, real-world case discussions, technical demonstrations, and group activities.

    Course Objectives:

    • To understand industrial production engineering concepts relevant to flexible packaging.

    • To explore methods of efficient plant layout, production planning, and process optimization.

    • To identify different types of production waste and learn methods of minimization.

    • To develop strategies for waste segregation, reuse, and sustainable disposal.

    • To promote industry best practices for operational efficiency and environmental compliance.

    Target Audience:

    • Plant engineers, production supervisors, and factory managers.

    • Industrial engineering professionals in the packaging sector.

    • Quality control and assurance teams.

    • Sustainability and EHS officers.

    • Entrepreneurs and SME owners in the flexible packaging industry.

    Day 1: Industrial Production Engineering in Flexible Packaging

    1. Overview of Production Engineering in Packaging:

      • Role of industrial engineering in packaging factories.

      • Process flow: raw materials to finished goods dispatch.

    2. Factory Layout & Equipment Efficiency:

      • Efficient floor layout for extrusion, printing, lamination, slitting, pouching.

      • Utility planning: power, compressed air, HVAC, waste ducting.

      • Machine uptime vs downtime analysis.

    3. Production Planning & Job Scheduling:

      • MRP systems in packaging operations.

      • Order-to-delivery workflow optimization.

      • Real-time tracking and machine loading plans.

    4. Lean Manufacturing & Productivity Improvement:

      • Introduction to 5S, Kaizen, TPM in packaging.

      • Line balancing, OEE, and bottleneck analysis.

      • Tools for reducing overproduction, idle time, and setup loss.

    Day 2: Waste Management in Flexible Packaging

    1. Types & Sources of Waste in Packaging Plants:

      • Process waste: trimmings, setup reels, print mismatches.

      • Rejection due to print, lamination, pouching defects.

      • Utility waste and material spillage.

    2. Waste Categorization and Segregation:

      • Identifying biodegradable, recyclable, reusable, and hazardous waste.

      • Color coding, bin design, and in-line segregation.

    3. Waste Reduction, Reuse & Recycling Strategies:

      • Edge trim recycling in extrusion.

      • Ink & solvent reuse techniques.

      • Selling, repurposing, or composting waste.

    4. Environmental Management & Compliance:

      • Local (DoE, BSTI) and international (ISO 14001, GMP) requirements.

      • Air/water emissions, effluent treatment, and reporting.

      • Sustainability KPIs and documentation.

    5. Final Group Activity and Assessment:

      • Participants design a waste management framework for a sample plant.

      • Include collection systems, reduction strategies, and monitoring plans.

      • Presentation and feedback session.

    Course Materials:

    • Course guidebook on production and waste engineering.

    • Process flow charts, layout samples, and waste maps.

    • Case studies from successful local and global packaging factories.

    • Forms and templates for audit and waste tracking.

    • Feedback and quiz sheets.

    Evaluation and Feedback:

    • Daily interactive quizzes and summary discussions.

    • Final day group presentation and peer review.

    • Instructor and participant feedback forms.