RESEARCH PAPER
Optimization of Hydraulic Oil Consumption in Metal Packaging Production Lines Using A3 Problem-Solving
1
Department od Mechanical Engineering, Manisa Celal Bayar University, Turkey
2
Department of Mechanical Engineering, Manisa Celal Bayar University, Turkey
3
Department of Electronic and Automation, Manisa Calal Bayar University, Turkey
A – Conceptualization; B – Methodology; C – Software; D – Validation; E – Formal analysis; F – Investigation; G – Resources; H – Data curation; I – Writing – original draft; J – Writing – review & editing; K – Visualization; L – Supervision; M – Project administration; N – Funding acquisition
Submission date: 2026-01-06
Final revision date: 2026-03-18
Acceptance date: 2026-04-20
Online publication date: 2026-07-11
Corresponding author
KEYWORDS
Sustainable ManufacturingResource EfficiencyA3 Problem-SolvingHydraulic Oil OptimizationMetal Packaging Industry
TOPICS
ABSTRACT
This study investigates hydraulic oil consumption in a high-precision metal packaging production line and implements targeted engineering improvements within the A3 problem-solving framework to reduce oil consumption and improve resource efficiency. A comprehensive data-driven analysis was conducted on Bodymaker units to identify process deviations through statistical evaluation and root-cause analysis. Based on the findings, key engineering improvements were implemented, including plate heat exchanger integration, sealing system upgrades, and digital pressure monitoring technologies. As a result, oil consumption decreased from 62.19 g/1000 cans to 39.5 g/1000 cans, achieving the target threshold and providing an annual saving of approximately $41,632. The results highlight the effectiveness of integrating engineering-based interventions with structured problem-solving methodologies. The study demonstrates a practical and scalable framework for improving maintenance performance and resource efficiency in industrial manufacturing systems.
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| eISSN: | 2956-3860 |
| ISSN: | 1507-2711 |
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