Abstract
In this research paper, we have used lean tools that are applicable in various faster growing industries like FMCG, pharmaceuticals; hospitality, manufacturing etc are used. The tool that is given the priority over others in identifying the waste is Value stream mapping. Value stream mapping is a lean tool that is used to translate both information and flow of data through which those processes that are not adding any positive value in our study can be easily eliminated. This paper is an effective effort to find out the waste production during manufacturing of a perishable goods in discrete manufacturing system. Pareto chart has been used to categories the factors that are responsible for the 80 percent of waste. Here Ishikawa diagram has played a vital role for finding of their possible causes and effect. Other contemporary lean tools like Kanban, Kaizen, and FIFO are used for future state map processing. The result obtained through the future state value stream map states the changeover time of various processes, the cycle time near to the takt time, improvement in lead time and total cycle time of the manufacturing process
Highlights
Lean manufacturing is a philosophy which was initially developed by Toyota, it is views as an approach to systematically identify the waste generating factors in the organization and remove the waste through continuous improvement and synchronizing the product flow at the pull of the customer
The below figure showing the future state value stream mapping the same thing done for kaju katli mainly the implementation of Kanban supermarket pull system, FIFO lane and combining two process so that the environment of customer pull system is created in the manufacturing process and there is significant reduction of lead time occur by which there is high impact on process efficiency of the process
Applications of lean tools have been vast field in Fast-Moving Consumer Goods (FMCG)’s but its implementation in mass production is great for the food industrial company for waste management
Summary
Lean manufacturing is a philosophy which was initially developed by Toyota, it is views as an approach to systematically identify the waste generating factors in the organization and remove the waste through continuous improvement and synchronizing the product flow at the pull of the customer. The process and material which are not adding any value to the product is a waste as per customer perspective so the motive of lean is to remove this non-value adding process and material from the system. The lean manufacturing system is comprising of many tools which help in to detect the waste and try to mitigate the effect of factors causing waste. Lean works with the integration of all the employees in an organization so the involvement of each employee in the organization is necessary for the successful implementation of tools. Nowadays lean is use with six sigma for reducing the variability in process
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