An implementation of lean technology to improve the lead time of syrup batching process and reduce hot fill line downtime

Abstract

The research would present an effective performance of lean tools implementing in an Lemon Tea processing line of a Drink Industry as a case study. An improved strategy to reduce the lead time of syrup batching process and then reduce downtime on hot fill line would be considered as well as used. The DMAIC (Define - Measure - Analyze - Improve - Control) methodology would be followed. As the results, the lead time of syrup batching process was reduced from around 140 minutes to (after implementation of lean technology) 98 minutes, and downtime on hot fill line was also dropped significantly by approximately 50 percent. Besides, the production flow was optimized by minimizing several non value added activities and time such as waiting time at the bottleneck points, machine breakdown, queuing time, and other unnecessary waiting time. Eventually, this case study would be useful in developing a generic approach to design lean environment in management system of the studied drink industry organization.