Application of lean tools in food manufacturing industries to improve productivity

Abstract

Lean manufacturing principles and instruments have been widely applied in food manufacturing companies during the recent past. Already a successful management philosophy. Lean tools were applied in food production process of selected product in this research to identify and implement improvements. The focus is to sanitize the equipment and optimize the food production process with 5S and Value Stream Mapping and enhance overall food manufacturing efficiency and have ongoing productivity by eliminating common bottlenecks. With a focus on the product selected, this study will examine current practices, utilize cutting-edge techniques and provide recommendations for improved overall rate of production. The main tools used in this study were Value Stream Mapping (VSM) and 5S. VSM was used for mapping accessible current state of the manufacturing process, review inefficiencies and plan for the future state. Meanwhile, 5S was used to keep the working space in order, improve efficiency and discipline of operations. The tools were embraced because they have a proven history in Lean Manufacturing and continuous improvement. The process was measured before the enhancements were implemented to establish a baseline. The process was re-measured after VSM and 5S had been implemented, in order to identify the impact of the enhancements. Results through support of lean tools enhanced productivity by 6.7% and lead time by 5 minutes. Significant benefit was achieved through the application of Value Stream Mapping together with 5S to improve manufacturing industries. Significant improvement in efficiency, organization and overall productivity was unveiled from the outcomes. The findings indicate the need for formal project management and strategic presentation of lean tools in food manufacturing industry. Improvements in the manufacture process of the selected product is a testimony that 5S and VSM could drive process enhancement. The research provides practical suggestions to manufacturing practitioners who hope to implement the same changes on their own process. The contribution and novelty of this research is in applying and comprehensive examination of Value Stream Mapping (VSM) and 5S framework to prove their combined effect on increasing efficiency, organization and productivity of the production process of the selected product.