Lean manufacturing system implementation: a case study in food processing company

Abstract

This research identified the critical major Non Value Added activity (MUDA); Motion, Defects/Errors and Waiting waste that exist in the case study company. The case study will be conduct at one of the local biggest Broiler Integrator Food Processing Company namely PPNJ Poultry & Meat Sdn. Bhd. located in Machap, Johor. This case study will used some approaching way such as observation on day to day working task during GEMBA, interviewing a personnel face to face and some documentation and record review from respective department. The critical major Non-Value Added activity will be analyzed based on the outcome from Waste Walk assessment than will be conducted during GEMBA at processing floor. The analysis will follow through after all the methodology implemented. Cause and Effect diagram will be used in order to identify potential root cause contribute to the major waste. An effective problem solving tools; P-D-C-A tools will be used to plan for the improvement as well as giving the beneficial solution for the company. All the potential solutions that suggested can be beneficial to the company in terms of money and time savings. This idea will directly help the company to increase their productivity, producing good quality products as well as providing good environment to their employees. The new workstation design will help the company eliminates all major critical waste and create smooth and efficient production. Output from this real study will be used for establishments and development of Lean Manufacturing System in food processing industry. These guidelines can be used for implement effectiveness Lean Manufacturing System in all organizations.