ArticlePDF Available

Lean manufacturing in food and beverage industry

Authors:
P. Kezia
P. Kezia
P. Kezia
  • This person is not on ResearchGate, or hasn't claimed this research yet.
K.S. Kumar
K.S. Kumar
K.S. Kumar
  • This person is not on ResearchGate, or hasn't claimed this research yet.
B.L.N. KRISHNA Sai at Vellore Institute of Technology University
B.L.N. KRISHNA Sai
Download full-text PDF
Read full-text
Download citation

Abstract

Current manufacturing industry is putting continuous efforts for its survival in the current impulsive and competitive economy. The concept of lean manufacturing was developed for maximizing the resource utilization through minimization of waste, later on lean was formulated in response to the fluctuating and competitive business environment. Due to rapidly changing business, the moulding industry is basically more focussed in bringing out new makes which are not only impressive as per the look but also is competing in the quality and pricing. The present review concentrates on the food Industrial manufacturing with a think of lean concept. Also, the study emphasizes the procedure of lean manufacturing and its benefits. Apart from the positive aspect of lean manufacturing, the drawbacks in the present industry and the possible measures to overcome for the safety and beneficial production is seen.
Content uploaded by B.L.N. KRISHNA Sai
Author content
All content in this area was uploaded by B.L.N. KRISHNA Sai on Feb 23, 2019
Content may be subject to copyright.
http://www.iaeme.com/
IJCIET/index.
International Journal of Civil Engineering and Technology (IJCIET)
Volume 8, Issue 5, May
2017, pp.
Available online at
http://www.iaeme.com/IJCIET/issues.
ISSN Print: 0976-
6308 and ISSN Online: 0976
© IAEME Publication
LEAN MANUFACTURING I
BEVERAGE
P.Kezia, K. Shravan Kumar
MLR
Institute o
ABSTRACT
Current manufacturing industry is putting continuous efforts for its survival in
the current impulsive and competitive economy. The concept of lean manufacturing
was developed for maximizing the resource utilization through minimization of waste,
lat
er on lean was formulated in response to the fluctuating and competitive business
environment. Due to rapidly changing business, the moulding industry is basically
more focussed in bringing out new makes which are not only impressive as per the
look but al
so is competing in the quality and pricing. The present review concentrates
on the food Industrial manufacturing with a think of lean concept. Also, the study
emphasizes the procedure of lean manufacturing and its benefits. Apart from the
positive aspect o
f lean manufacturing, the drawbacks in the present industry and the
possible measures to overcome for the safety and beneficial production is seen.
Key words :
Food Industry, Lean, Manufacturing, Packaging, Waste
Cite this Article:
P.Kezia, K. Shravan Kumar and B.L.N.Krishna Sai Lean
Manufacturing in Food and Beverage Industry
Engineering and Technology
http://www.iaeme.com/IJCIET/issues.
1. INTRODUCTION
Plastic Bottles nowadays is something that is in high demand, is it mainly because of its
durability. Majority of people around the world use it in a daily basis. Containing innumerous
uses, plastic bottles or plasti
c to be specific, must be one of the greatest discoveries in the
recent centuries. Plastic bottles were first used commercially in 1875
expensive until the early 1960s when high
beca
me popular with both manufacturers and customers due to their lightweight nature and
relatively low production and transportation costs compared with
biggest advantage plastic bottles have over glass is their superior resistance
both production and transportation. Except for wine and beer, the
completely replaced glass bottles with plastic bottles.
In the current era of globalization, industries are adopting new tools and techniques to
produce goods to compete and survive in the market. The most daunting issue faced by
IJCIET/index.
asp 168
editor@iaeme.com
International Journal of Civil Engineering and Technology (IJCIET)
2017, pp.
168–174, Article ID: IJCIET_08_05_020
http://www.iaeme.com/IJCIET/issues.
asp?JType=IJCIET&VType=8&IType=5
6308 and ISSN Online: 0976
-6316
Scopus Indexed
LEAN MANUFACTURING I
N FOOD AND
BEVERAGE
INDUSTRY
P.Kezia, K. Shravan Kumar
and B.L.N.Krishna Sai
Department Of Mechanical Engineering
,
Institute o
f Technology, Hyderabad, India.
Current manufacturing industry is putting continuous efforts for its survival in
the current impulsive and competitive economy. The concept of lean manufacturing
was developed for maximizing the resource utilization through minimization of waste,
er on lean was formulated in response to the fluctuating and competitive business
environment. Due to rapidly changing business, the moulding industry is basically
more focussed in bringing out new makes which are not only impressive as per the
so is competing in the quality and pricing. The present review concentrates
on the food Industrial manufacturing with a think of lean concept. Also, the study
emphasizes the procedure of lean manufacturing and its benefits. Apart from the
f lean manufacturing, the drawbacks in the present industry and the
possible measures to overcome for the safety and beneficial production is seen.
Food Industry, Lean, Manufacturing, Packaging, Waste
.
P.Kezia, K. Shravan Kumar and B.L.N.Krishna Sai Lean
Manufacturing in Food and Beverage Industry
.
International Journal of Civil
Engineering and Technology
, 8(5), 2017, pp. 168–174.
http://www.iaeme.com/IJCIET/issues.
asp?JType=IJCIET&
VType=8&IType=5
Plastic Bottles nowadays is something that is in high demand, is it mainly because of its
durability. Majority of people around the world use it in a daily basis. Containing innumerous
c to be specific, must be one of the greatest discoveries in the
recent centuries. Plastic bottles were first used commercially in 1875
but remained relatively
expensive until the early 1960s when high
-density
polyethylene was introduced. They quickly
me popular with both manufacturers and customers due to their lightweight nature and
relatively low production and transportation costs compared with
glass bottles. However, the
biggest advantage plastic bottles have over glass is their superior resistance
both production and transportation. Except for wine and beer, the
food industry
completely replaced glass bottles with plastic bottles.
In the current era of globalization, industries are adopting new tools and techniques to
produce goods to compete and survive in the market. The most daunting issue faced by
editor@iaeme.com
asp?JType=IJCIET&VType=8&IType=5
N FOOD AND
Current manufacturing industry is putting continuous efforts for its survival in
the current impulsive and competitive economy. The concept of lean manufacturing
was developed for maximizing the resource utilization through minimization of waste,
er on lean was formulated in response to the fluctuating and competitive business
environment. Due to rapidly changing business, the moulding industry is basically
more focussed in bringing out new makes which are not only impressive as per the
so is competing in the quality and pricing. The present review concentrates
on the food Industrial manufacturing with a think of lean concept. Also, the study
emphasizes the procedure of lean manufacturing and its benefits. Apart from the
f lean manufacturing, the drawbacks in the present industry and the
possible measures to overcome for the safety and beneficial production is seen.
P.Kezia, K. Shravan Kumar and B.L.N.Krishna Sai Lean
International Journal of Civil
VType=8&IType=5
Plastic Bottles nowadays is something that is in high demand, is it mainly because of its
durability. Majority of people around the world use it in a daily basis. Containing innumerous
c to be specific, must be one of the greatest discoveries in the
but remained relatively
polyethylene was introduced. They quickly
me popular with both manufacturers and customers due to their lightweight nature and
glass bottles. However, the
biggest advantage plastic bottles have over glass is their superior resistance
to breakage, in
food industry
has almost
In the current era of globalization, industries are adopting new tools and techniques to
produce goods to compete and survive in the market. The most daunting issue faced by
Lean Manufacturing in Food and Beverage Industry
http://www.iaeme.com/IJCIET/index.asp 169 editor@iaeme.com
manufacturers today is how to deliver their products or materials quickly at low cost and
good quality. One promising method for addressing this issue is the application of lean
management principles and techniques. Lean manufacturing is a set of tools and
methodologies that aims for the continuous elimination of wastes throughout the production
cycle. Companies that do not institute continuous improvement after implementing process
innovation are likely to revert to old practices Lean manufacturing (LM) has shown to be a
good example of process innovation in companies, having continuous improvement as one of
its cornerstone. Regarding implementation, LM is seen as not easily applicable to industries
with large batch processes such as the food and beverage industries.
It is generally perceived that LM principles cannot be easily be applicable in food
industry as the other industries. As the food is not make to order kind of manufacturing and
also the quality of the packaging material needs to be closely managed for the wellness and
safety of the people. However, evidence found in the literature suggests that LM can be
successfully carried out for the foods such as red meat, bakery items, condiments, pizza,
sauce, ketchup, frozen food etc.
A lean strategy with the accompanying training and problem-solving sessions will
provide "new eyes" for management and workers to first see the hidden waste and then to
begin to eliminate waste. Once these eyes are seeing waste, then motivation and creativity to
include safety and sustainability in the lean efforts strengthen the benefits [1]. The progress in
lean implementation is snail-paced and needs to be augmented when seen for food industry.
However, Lean tools can be successfully implemented in a food manufacturing company to
improve production efficiency, to improve product quality, and to reduce production cost by
reducing waste and adding value [2]. Lean manufacturing is not a magical solution. It
involves a change in leadership that requires considerable communication, coordination, and
organization which results in a change in the company’s culture. In order to create a lean
manufacturing environment, the organization needs to be aware of where it is at that point.
They must know why they need to change and why change is important. It is necessary to
provide the answers to these questions to employees so they become more engaged in the
process [3]. The ultimate lean target is the total elimination of waste. Waste, or muda, is
anything that adds cost to the product without adding value [4]. In one of the article author
has made the research in two case studies and traced out the problems being faced for LM, as
for stating few, the breakage of glass bottles, change over’s needed for dies and punches,
frequent changes in design of packaging bottles , cans and tins [5]. Implementing the concept
of lean does not mean that the quality is going down. Problem with quality happens in all the
systems, but quick inspection and every worker involved in solving technical issues rather
than ignoring makes the uniqueness of lean pointing towards quality [6].
2. MANUFACTURING METHODOLIGIES
2.1. Different Ways of Manufacturing Employed in Food and Beverage Industry
Aseptic packaging has been developed as a result of the market's demand of a method of
packaging natural products. Thus, the evolution of packaging technology has been:
Cans: This way of packaging is used by roughly 90% of the market. However, this kind of
packaging is using more and more aseptic packaging techniques. Asepton Drum: It meant a
revolution as a substitute of 5 Kg. cans that are used in the industrial sector. It is a high
technology drum, made of cold rolled steel sheet and internally lined with anun plasticized,
food grade, PVC film. It is primary used for the packaging of liquid and semi liquid food
products, like juices, pulps, purees and concentrates. It maintains the quality of the product
and can be re-uses several times once emptied. Tetra Pak's range: This kind of packaging is
P.Kezia, K. Shravan Kumar and B.L.N.Krishna Sai
http://www.iaeme.com/IJCIET/index.asp 170 editor@iaeme.com
well known by most of the people. It is very well introduced in the milk, dairy and beverage
industries. It is not a suitable type of packaging for industrial volumes. Products with fibres
and particulates cannot be filled. Alternatives: PKL, Glass bottles, jars and PET. Glass is
losing momentum in the market and PET is developing fast for the aseptic filling of juices
and beverages. Frozen foods: Freezing of foods enables the best quality products, but it is not
a well established technology for industrial purposes. Applications of HRS aseptic fillers.
Aseptic filling can be used for any type of fluid or doughy product processed by the food
industry. In order to satisfy all requirements, producers of aseptic bags use various kinds of
materials: high-barrier, multi-layer, flexible laminates, transparent or dull, coextruded,
metalized of provided aluminium foils. Bag-in-box & Bag-in-drum: 55 gallon bags. These
bags, available in metalized material (simple or high barrier) or coextruded material, are
produced both for the European market associated with conical drums. Traditional products
such as tomato concentrate, paste and pulp, citrus fruits juice and fruit puree, they are
produced with 1 inch spout. For delicate products such as diced tomato and diced fruit 2
inches closures are used. Gusseted bags up to 220 litres. The typical gusseted bag is adaptable
to any kind of external box, steel drum, cardboard box, plywood box, and jute bag. Modern
bags guarantee an excellent barrier to oxygen. Such bag offers a capacity of 5, 10, and 20
litres also. Big size bags. Big size bags up to 1000 litres have been developed with particular
care towards practical handling, transport and storage. Form-Fill-Seal (FFS) packaging:
Form-Fill-Seal technology allows producing of finished packages (filled, closed and
labelled), in a single process, starting from reels of material. Bags are available in formats up
to 0.5, 1, 5, 10, 15 and 20 liters, and are manufactured with metalized or coextruded material.
2.2. Current Packaging in Food Industry and Implementation of Lean Concept
The complexity of the factory will also have an impact on the methods of production. The
rapidly changing fashions in food mean that no one in the food supply chains want to get
caught with excess stock. There is nothing worse than having a large stock of a specialist raw
material when the fashion changes, except perhaps having a large stock of packaging
material. As a result, manufacturing operations have to be set up to be very flexible to meet
demand. The way that food manufacturers have responded to the food fashion aspect of the
business is to make little and often. This has always been a feature in short shelf-life foods,
such as chilled products, bread and fresh produce, but is increasingly used in factories that
manufacture long-life products, such as frozen and canned foods, biscuits and preserves.
Food fashion has taken food manufacturers into the area of low stocks and flexible
manufacturing. This appears on the shop-floor as short production runs, multiple line
changeovers, complex material controls and a need for precise, right-first-time production.
One of the food packaging companies, the process being followed is seen the following
way; the first process in plastic injection moulding is the drying process. The purpose of
drying is to remove moisture content in plastic resin before further process. Dryness is
important to ensure a common surface defect such as silver streaks does not occur during
processing. The next process is injection moulding. The process begins with setup process.
Current practice of setup process takes at least 2 hours to complete. Setup instruction which
contain important parameters such as temperature, speed, pressure, stroke, shot volume, and
time is used as a guide to avoid trial and error practice. Upon completion of setup process, 2
shots of sample have been submitted for buy-off by QC technician. After the confirmation,
production is allowed to run as per scheduled. For semi automatic operation, 1 headcount is
allocated per shift to run the machine. For the big automatic part, 1 headcount per shift is
allocated to perform visual inspection, deburring and packing. Another 1 headcount is
allocated to collect and pack all small automatic parts. In-process inspection is performed
every 3 hourly according to the inspection plan for every individual part. The main criteria
Lean Manufacturing in Food and Beverage Indus
http://www.iaeme.com/
IJCIET/index.
are con
trolled dimensions and visual inspection. Finally, outgoing QC is performed every 2
hourly according to sampling plan for visual inspection. The material flow and sequence of
the main processes were sketched on a paper. The material flow from supplier to t
warehouse was done weekly based upon the requirement from customer. It is delivered to the
plastic moulding raw material store daily upon request. The plastic resin will be transferred to
the centralized drying area using a manual pallet truck. Aft
duration of 4 hours drying, plastic resin will be conveyed automatically to the designated
machines based on type of plastic used for production. There are at least 5 types of common
plastic resin used for production. They are AB
parts will be sent to the outgoing QC area for final inspection. After that, moulded parts will
be kept temporarily in the plastic part store. Moulded part will be sent to customer by electric
pallet truck daily upo
n request.
2.3.
Elimination of Wastes in t
Many manufacturers look at process improvement, safety and recycling as separate programs,
they would benefit from viewing lean, safety and sustainability as three fibres making a
single rope us
ed in the improvement journey. Just as a rope is made stronger with multiple
fibres wrapped to make one, making lean, safety and sustainability one initiative can make
your plant stronger. Generally, the relentless pursuit of eliminating waste, the essence
is to eliminate waste and wasteful practices that are hidden. A lean strategy with the
accompanying training and problem
management and workers to first see the hidden waste and then to begin to elimina
Once these eyes are seeing waste, then motivation and creativity to include safety and
sustainability in the lean efforts strengthen the benefits.
Transport adds no value to the product, as a business are paying people to move material
from
one location to another, a process that only costs money and makes no value. The
of transport
can be a very high cost to the business, as one needs people to operate it and
equipment such as trucks or fork trucks to undertake this expensive movement
Inventory costs money, every piece of product tied up in raw material, work in progress or
finished goods has a cost and until it is actually sold that cost is for company [8]. In addition
to the pure cost of the inventory it adds many other
Inventory has to be stored, it needs space, it needs packaging and it has to be transported
around. It has the chance of being damaged during transport and becoming obsolete.
The waste of Inventory
hides many of th
Figure 1
The basic concept behind waste management is the
approaches to managing waste are at the top. Waste management is in contrast to waste
minimization. Waste
minimization
Lean Manufacturing in Food and Beverage Indus
try
IJCIET/index.
asp 171
editor@iaeme.com
trolled dimensions and visual inspection. Finally, outgoing QC is performed every 2
hourly according to sampling plan for visual inspection. The material flow and sequence of
the main processes were sketched on a paper. The material flow from supplier to t
warehouse was done weekly based upon the requirement from customer. It is delivered to the
plastic moulding raw material store daily upon request. The plastic resin will be transferred to
the centralized drying area using a manual pallet truck. Aft
er going through a minimum
duration of 4 hours drying, plastic resin will be conveyed automatically to the designated
machines based on type of plastic used for production. There are at least 5 types of common
plastic resin used for production. They are AB
S, PC, PA6, PA66 and PC+ABS. All moulded
parts will be sent to the outgoing QC area for final inspection. After that, moulded parts will
be kept temporarily in the plastic part store. Moulded part will be sent to customer by electric
n request.
Elimination of Wastes in t
he Present Industry
Many manufacturers look at process improvement, safety and recycling as separate programs,
they would benefit from viewing lean, safety and sustainability as three fibres making a
ed in the improvement journey. Just as a rope is made stronger with multiple
fibres wrapped to make one, making lean, safety and sustainability one initiative can make
your plant stronger. Generally, the relentless pursuit of eliminating waste, the essence
is to eliminate waste and wasteful practices that are hidden. A lean strategy with the
accompanying training and problem
-
solving sessions will provide "new eyes" for
management and workers to first see the hidden waste and then to begin to elimina
Once these eyes are seeing waste, then motivation and creativity to include safety and
sustainability in the lean efforts strengthen the benefits.
Transport adds no value to the product, as a business are paying people to move material
one location to another, a process that only costs money and makes no value. The
can be a very high cost to the business, as one needs people to operate it and
equipment such as trucks or fork trucks to undertake this expensive movement
Inventory costs money, every piece of product tied up in raw material, work in progress or
finished goods has a cost and until it is actually sold that cost is for company [8]. In addition
to the pure cost of the inventory it adds many other
costs; inventory feeds many other wastes
Inventory has to be stored, it needs space, it needs packaging and it has to be transported
around. It has the chance of being damaged during transport and becoming obsolete.
hides many of th
e other wastes in your systems.
Figure 1
Hierarchy of reducing waste.
The basic concept behind waste management is the
waste hierarchy
, where the most effective
approaches to managing waste are at the top. Waste management is in contrast to waste
minimization
involves efforts to minimize
resource
editor@iaeme.com
trolled dimensions and visual inspection. Finally, outgoing QC is performed every 2
hourly according to sampling plan for visual inspection. The material flow and sequence of
the main processes were sketched on a paper. The material flow from supplier to t
he main
warehouse was done weekly based upon the requirement from customer. It is delivered to the
plastic moulding raw material store daily upon request. The plastic resin will be transferred to
er going through a minimum
duration of 4 hours drying, plastic resin will be conveyed automatically to the designated
machines based on type of plastic used for production. There are at least 5 types of common
S, PC, PA6, PA66 and PC+ABS. All moulded
parts will be sent to the outgoing QC area for final inspection. After that, moulded parts will
be kept temporarily in the plastic part store. Moulded part will be sent to customer by electric
Many manufacturers look at process improvement, safety and recycling as separate programs,
they would benefit from viewing lean, safety and sustainability as three fibres making a
ed in the improvement journey. Just as a rope is made stronger with multiple
fibres wrapped to make one, making lean, safety and sustainability one initiative can make
your plant stronger. Generally, the relentless pursuit of eliminating waste, the essence
of lean
is to eliminate waste and wasteful practices that are hidden. A lean strategy with the
solving sessions will provide "new eyes" for
management and workers to first see the hidden waste and then to begin to elimina
te waste.
Once these eyes are seeing waste, then motivation and creativity to include safety and
Transport adds no value to the product, as a business are paying people to move material
one location to another, a process that only costs money and makes no value. The
waste
can be a very high cost to the business, as one needs people to operate it and
equipment such as trucks or fork trucks to undertake this expensive movement
of materials.
Inventory costs money, every piece of product tied up in raw material, work in progress or
finished goods has a cost and until it is actually sold that cost is for company [8]. In addition
costs; inventory feeds many other wastes
Inventory has to be stored, it needs space, it needs packaging and it has to be transported
around. It has the chance of being damaged during transport and becoming obsolete.
, where the most effective
approaches to managing waste are at the top. Waste management is in contrast to waste
resource
and energy use
P.Kezia, K. Shravan Kumar and B.L.N.Krishna Sai
http://www.iaeme.com/IJCIET/index.asp 172 editor@iaeme.com
during manufacture. For the same commercial output, usually the less materials are used, the
less waste is produced. Cradle-to-grave concept which is the full Life Cycle Assessment from
resource extraction ('cradle') to use phase and disposal phase ('grave'). In case of trees
produce paper, which can be recycled into low-energy production cellulose (fiberised
paper) insulation, then used as an energy-saving device in the ceiling of a home for 40 years,
saving 2,000 times the fossil-fuel energy used in its production.
Scraps can be immediately re-incorporated at the beginning of the manufacturing line so
that they do not become a waste product. Steps can be taken to ensure that the number of
reject batches is kept to a minimum. This is achieved by increasing the frequency of
inspection and the number of points of inspection. Installing automated continuous
monitoring equipment can help to identify production problems at an early stage. When the
beverage bottling is considered, many a times, the PET being used has a slight damage which
is brought into the lime light after filling it, hence it is scrapped. It not only wastes the
beverage but also the packaging material, time of the labour, Machinery time, Handling time
bringing the total efficiency down. Therefore improved quality control and process
monitoring system is necessary to reduce the waste up to certain extent.
Waste exchanges are where the waste product of one process becomes the raw material
for a second process. Waste exchanges represent another way of reducing waste, disposal
volumes for waste that cannot be eliminated [7]. Also, unnecessary motions are those
movements of man or machine which are not as small or as easy to achieve as possible, by
this bending down to retrieve heavy objects at floor level when they could be fed at waist
level to reduce stress and time to retrieve. Excessive travel between work stations, excessive
machine movements from start point to work start point are all examples of the waste of
Motion. The waste of over processing is where we use inappropriate techniques, oversize
equipment, working to tolerances that are too tight, performs processes that are not required
by the customer and so forth. All of these things cost us time and money.
3. IMPROVEMENTS THAT CAN BE MADE IN THE PACKAGING
INDUSTRY
Looking at reducing pack weight and using modified atmosphere packaging or improved seal
integrity techniques to reduce the risk of food waste can be made. By using returnable, re-
usable transit packaging material to reduce secondary packaging waste. Only If cutting off the
catering packs does not create food waste due to product deterioration, Catering packs can
also minimize packaging waste. Improved packaging design can also reduce the carbon
impact of packaging. Redistributing the surplus food fit for human consumption can be
redistributed to commercial organizations or charities such as Plan Zheroes, Fare Share and
Food cycle. If not suitable for human consumption, investigate whether it can be sent for
animal feed. Recycling food where redistribution is not possible, one can consider
composting food waste or sending it for anaerobic digestion instead of disposal to landfill.
Improving packaging functionality, for example reclose able packs can be used. And also on
pack guidance, for example recycling, date labeling and storage freezing and defrosting
guidance can be made so as to utilize those packaging material up till that particular date
instead of disposing. For aluminium, the focus will be on increasing collection, through
recycling at work, local authority foil and can collections, and investment in on-the-go
infrastructure.
Lean concept is being employed by few of the manufacturers in the present era. Few
examples being, Marks and Spencer changed the plastic tray used to protect its beef to a thin
skin pack wrapped tightly around the product. This method cut the packaging down by 69%
and extended the shelf life of the product by four days. Coca-Cola has reduced the weight of
Lean Manufacturing in Food and Beverage Industry
http://www.iaeme.com/IJCIET/index.asp 173 editor@iaeme.com
its soft drink cans by 5%, potentially saving 15,000 tonnes of packaging a year across the
European aluminium can sector. This represents approximately 78,000 tonnes of CO2 the
equivalent of taking 25,000 cars off the road. Heinz has changed the design of its ‘easy open’
can ends, saving 1,400 tonnes of steel without any effect on the performance of the cans and
saving Heinz in the region of $750,000 in production costs worldwide.
4. CONCLUSION
Packaging policy should minimize the environmental impact of packaging over its whole life
cycle, without compromising its ability to protect the product. Lean manufacturing starts with
optimizing packaging through recyclability, reusability and recovery as a standard and market
innovation and development which meet the growing demand for re-useable and recycled
packaging, across all types of packaging. Keeping apart packaging stuff, other factors which
are having major impact is the transportation costs, Inventory costs, production problems and
shelf life are also showing a great impact. Reducing the handling time control over
production of cheap packaging covers, trays, bottles, bowls etc is ought to be reduced to a
great extent reason being less quality material is proportional to the damaged packs making
secondary packaging necessary. This overcomes the wastes from defective items and also
overproduction as well as handling costs. Wastes are being recycled to a great extent which is
a good hint for the manufacturing industry, but over processing of the recycled goods so as
not to show up the decolouration to the customer, the strength of the material is deteriorating
thereby making unnecessary costs of over processing. As far as longevity and visibility of the
packings and bottling are concerned, the quality material with the proper manufacturing and
expiry dates can be printed by the business people so that trash of packing is reduced by
reusing.
Though the lean concept is being used by few of the company’, food and beverage
industry has 25% to 30% success rate. As Recycling prevents resource destruction, prevents
pollution, saves energy, saves money and also creates jobs, throughout the world plastic and
PET has a great sway, making its impact on the public and Economy of the country. But the
ill effects of plastic are also up to great extent. This is due to recycling plastics are getting
diluted with the food items being packed within and the quality of recycling plastic not being
maintained etc. Public being very selective and cautious over the packaging and material used
for the packaging as well. Health and safety considerations add to the complexity of
processes, but do not alter the fact that they are still processes that can be improved. The
secondary issue being the vast food wastage, deterioration of packaging material by time.
Looking onto the other face, Lack of persistent and challenging leadership, Lack of a clear
vision of the future and of what is possible to be achieved, Lack of patience and follow
through, Failure to perceive that lean is a viable strategy to help achieve competitive
advantage and Lack of constant visibility by management on the shop floor are also probable
and most likely reasons for the underlying of lean manufacturing in Food and beverage
Industry.
REFERENCES
[1] Glen miller and Christian Paulson, Lean, Clean and Green Food Processing, Sustainable
plant June, 2010.
[2] Ian Kennedy, Andrew Plunkett, Julfikar Haide, Implementation of Lean Principles in a
Food Manufacturing Company, Advances in Sustainable and Competitive Manufacturing
Systems, pp. 1579-1590.
[3] Feld, W, Lean manufacturing: Tools, techniques, and how to use them (Boca Raton, FL:
St. Lucie Press, 2000).
P.Kezia, K. Shravan Kumar and B.L.N.Krishna Sai
http://www.iaeme.com/IJCIET/index.asp 174 editor@iaeme.com
[4] Tapping, D., Luyster, T., and Shuker, T, Value stream management: Eight steps to
planning, mapping, and sustaining lean improvements, Journal for Healthcare
Quality 25(6):47 · November 2003 (New York, NY: Productivity Press, 2002).
[5] Rui Borges Lopes et al., Application of Lean Manufacturing Tools in the Food and
Beverage Industries, Technological manag. Innovations,10.
[6]
Lonnie Wilson, How to implement lean manufacturing (Tata Mcgrawhill, Edition
2,9,10, 21-22) pp.133-145
.
[7] Robert.L.Peacock, Barbara Peach, Steve Gibbs, Waste Management and minimization,
ISBN: 978-1-84826-119-8, 1, pp.154-169.
[8] Darren Dolcemascolo, Improving the extended value stream (Newyork: Productivity
Press,) pp.133-135.
[9] Yusuf Abdulfatah Abdu, Onu Peter , Uma Kant Gupta, Lean Concepts and Methods : 3P,
International Journal of Scientific Research in Computer Science, Engineering and
Information Technology, 1, 2, ISSN : 2456-3307.
... In addition, when Lean becomes a culture, organizations improve their value chains and benefit not only their processes but also their workforce's talents and customers' satisfaction. Such is the case in different sectors, including the automotive field [12], food and beverages [13], and healthcare [14]. ...
... The implementation of Lean in organizations has significantly benefited various sectors including the automotive field [12], food and beverages [13], and healthcare [14]. Particularly when Lean is integrated with new technologies, it has been identified in the literature as enhancing organizations' performance [33]. ...
A Maturity Model to Become a Smart Organization Based on Lean and Industry 4.0 Synergy
Article
Full-text available
  • Sep 2023
This paper proposes a maturity model (MM) to become a smart organization considering Lean as a key enabler to drive I4.0 adoption. A systematic literature review on I4.0 and Lean concepts plus I4.0 adoption models was conducted through the PRISMA method based on articles from Scopus and Web of Science databases, and records from official websites (e.g., consulting firms) published between 2011 and 2022. Identifying the Lean and I4.0 relationship and comparing the models’ relevant characteristics allowed the development of the MM proposal. Although previous research refers to Lean and I4.0 collaboration, the opportunity to design a reference model for adopting both approaches was identified since their interaction enhances value creation. The comprehensive model supports structuring the types of Lean principles/methods/tools and I4.0 technologies and their action to link them and define which of them need to be implemented according to the maturity level chronologically. Additionally, the proposed MM provides an adoption roadmap that starts eliminating non-added activities in the initial stages for process improvement to integrate I4.0 enabling technologies later. The model makes it possible for practitioners to generate implementation and development processes oriented toward I4.0 adoption based on maturity levels in which Lean has the starting point at the first ones. Hence, it defines the enabling technologies to be incorporated and linked throughout the value chain, enhancing a Lean culture. This model will help organizations to become “smart” by allowing them to transition toward the best technology investment and continuously add value to their processes, people, and products. Moreover, the results will motivate researchers to study further the application of models for I4.0 adoption in which Lean is integrated to fill the gap with the I4.0 embrace caused by quickly changing industrial environments and the uncertainty and unknowledge of guidelines associated with incorporating new technologies.
View
... It depends on the organizational characteristics, the right design for the implementation of simple production and its maintenance (Sousa & Voss, 2008) (Lopes, Freitas, & Sousa, 2015). Lean principles are used by a few companies in the food and beverage industry, with a success rate of 25% to 30% (Kezia, Kumar, & Sai, 2017). Thus, by reducing the supply chain or production cost, the quality is increased, or new or significantly improved products are produced (OECD, 2005). ...
... And by improving production efficiency, improving product quality, decreasing production costs, reducing waste, adding value and innovate the procedure. It is a new philosophy that leads production to a change at all stages of the production process and that requires communication, coordination, and organization to achieve a larger market share (Kezia et al., 2017). ...
Influence of anthropogenic factors on pollution of arable soils and changes in the activity of enzymes in them
Conference Paper
Full-text available
  • Dec 2022
The aim of this work was to combine biochemical and geo-ecological approaches to determine the degree of anthropogenic load on soils, taking into account the activity of some oxidoreductase (catalase) and hydrolytic (amylase, urease, and invertase) enzymes for comparative assessment of pollution of arable soils near the industrial zone of Hrazdan city. There are located Hrazdan Thermal Power Plant and Hrazdan Cement Plant. A soil sample from the point-area Hrazdan1 was located next to them. Taking into consideration that the wind was rising in the southwest direction, the third point-area Hrazdan3 was located in the same direction, at a distance of up to one kilometer from the industrial zone. The soil samples were determined for humus content, the activity of some enzymes, and d-elements of the fourth period, forming a group known as transitional heavy metals. With distance from the general industrial zone, taking into account all intermediate points of material sampling, a significant decrease in the concentration of transitional heavy metals was observed for the middle point-area (Hrazdan2). The values Zc showed that all the investigated point-areas were dangerously contaminated, but the middle point-area (Hrazdan2) had 15% lower values Zc compared to the extreme soil sampling points. As we moved away from the industrial zone from point-area Hrazdan3 toward point-area Hrazdan1, a significant increase in humus up to 25% was found in the soil samples against the background of a gradual increase in pH in the soil samples up to 7%. According to the activity of invertase and amylase enzymes, it is well seen that their activity in the point-area Hrazdan2 differs from the activity in other point-areas. Invertase activity in Hrazdan2 was on average 30% lower than in soil samples from Hrazdan1 and Hrazdan3.
View
... It depends on the organizational characteristics, the right design for the implementation of simple production and its maintenance (Sousa & Voss, 2008) (Lopes, Freitas, & Sousa, 2015). Lean principles are used by a few companies in the food and beverage industry, with a success rate of 25% to 30% (Kezia, Kumar, & Sai, 2017). Thus, by reducing the supply chain or production cost, the quality is increased, or new or significantly improved products are produced (OECD, 2005). ...
... And by improving production efficiency, improving product quality, decreasing production costs, reducing waste, adding value and innovate the procedure. It is a new philosophy that leads production to a change at all stages of the production process and that requires communication, coordination, and organization to achieve a larger market share (Kezia et al., 2017). ...
Investigation of the processes occurring in water of acid mine drainage during their exposure
Conference Paper
Full-text available
  • Dec 2022
The most actual environmental problem currently faced by the coal and metal mining industry is acid mine drainage. The aim of the article is to study a number of physicochemical properties of the acid mine drainage waters, which will serve as a basis for the development of new competitive approaches to their purification. Using inductively coupled plasma-optical emission spectrometry and pH-measurement processes occurring in the acid mine drainage waters under their long-term exposure under normal conditions were investigated. The drainage water of 10-days' exposure in the laboratory was studied. As a result of the oxidation of divalent iron into trivalent iron in the acid mine drainage waters the precipitation of iron as Fe(OH)3. Direct contact of water with atmospheric oxygen after the outlet initiated the oxidation process. In order to restore the true picture of the content of metal cations and sulfate ions, we analyzed both the water and the sediment, which was formed during water sedimentation. It has been reliably established that as the pH decreases, the turbidity of the source water increases, which has a linear character. The main, but not the only, component of the precipitate is Fe(OH)3, while its share in terms of Fe3+ is 64.01 wt %. But if calcium precipitates in the form of insoluble sulfates, then in the case of other metals, precipitation occurs with iron hydroxide in adsorbed form. In the case of the transition of sodium and magnesium to the precipitate, they are precipitated with iron hydroxide in adsorbed form. There is also a transition to the precipitate of sulfate ions. The gypsum nature of sulfate ions in the sediment is about 1/3 of the total sulfur content in the sediment. The rest of the sulfate ions are precipitated with iron hydroxide in adsorbed form.
View
... Nilai kinerja atribut pelayanan terkecil pada atribut pelayanan pemasaran produk sebesar 2,84 (baik). Menurut Kezia et al., (2017) Penggunaan kemasan untuk produk hendaknya dipertimbangkan berdasarkan bahan baku atau produk yang dibuat oleh perusahaan. Tingkat penilaian hasil kinerja pelayanan dapat dilihat pada Tabel 4. ...
Analisis Tingkat Kepuasan Konsumen Terhadap Kualitas Produk dan Jasa Pengiriman Wine Pada PT. PW
Article
  • Jan 2025
The purpose of this study was to determine the product and service attributes that are considered important by consumers, calculate the level of importance and performance to meet consumer satisfaction, and analyze the attributes that are prioritized to be improved based on the level of importance and consumer satisfaction at PT. PW. The study used a survey method and data analysis with the Importance Performance Analysis (IPA) method. The data obtained in the study came from distributing questionnaires to 38 respondents who were customers of PT. PW. The results showed that all product and service attributes were considered very important by consumers. The average value of the level of importance of product attributes was 3.71 (very important) and service attributes were 3.79 (very important). Overall, the average value of the product satisfaction level was 83.85% and the level of service satisfaction was 81.75%. Analysis of attributes that are the main priority to be improved on product attributes, namely wine color, wine volume size, wine benefits and quality of wine raw materials while for service quality which is the main priority is improved on wine product marketing attributes and wine product offering attributes. Keywords: wine, consumer satisfaction, Importance Performance Analysis (IPA). ABSTRAK Tujuan dari penelitian ini adalah untuk mengetahui atribut – atribut produk dan pelayanan yang dianggap penting oleh konsumen, menghitung tingkat kepentingan dan kinerja untuk memenuhi kepuasan konsumen, serta menganalisis atribut – atribut yang diprioritaskan untuk ditingkatkan berdasarkan tingkat kepentingan dan kepuasan konsumen di PT. PW. Penelitian menggunakan metode survei dan analisis data dengan metode Importance Performance Analysis (IPA). Data yang diperoleh dalam penelitian berasal dari penyebaran kuisioner kepada 38 responden yang merupakan pelanggan PT. PW. Hasil penelitian menunjukkan bahwa semua atribut produk dan pelayanan dianggap sangat penting oleh konsumen. Nilai rata-rata tingkat kepentingan atribut produk sebesar 3,71 (sangat penting) dan atribut pelayanan sebesar 3,79 (sangat penting). Secara keseluruhan nilai rata-rata tingkat kepuasan produk sebesar 83,85% dan tingkat kepuasan pelayanan sebesar 81,75%. Analisis atribut yang menjadi prioritas utama untuk ditingkatkan pada atribut produk, yaitu warna wine, ukuran volume wine, manfaat wine dan kualitas bahan baku wine sedangkan untuk kualitas pelayanan yang menjadi prioritas utama ditingkatkan pada atribut pemasaran produk wine dan atribut penawaran produk wine. Kata kunci : wine, kepuasan konsumen, Importance Perfomance Analysis (IPA).
View
... At the same time, the transformation of secondary resources into a conditioned useful product is carried out. This is promising, in particular, from the standpoint of commitment to lean manufacturing principles [2,3]. ...
Devising a technology for obtaining glued sausage casings from intestinal raw materials using electrophoresis
Article
Full-text available
  • Aug 2024
The object of research is the technique for obtaining glued sausage casings, in which adhesive related structures and electrophoresis for tanning are used to glue the layers of intestinal raw materials. Devising a technique for gluing sausage casings from intestinal raw materials with the use of adhesive related structures by stitching by tanning, via intensified electrophoresis, has been substantiated. The technology of glued sausage casings from intestinal raw materials, which are classified as unclaimed residues and waste, has been proposed. The technology differs from known similar technologies by applying a technique for gluing intestinal membranes using an adhesive related construct and electrophoresis during tanning. The devised gluing technique and the device for its implementation make it possible to avoid violation of the integrity of the raw material, are universal in relation to it, and are easy to operate. The rational parameters of electrophoresis, which is used to accelerate the tanning process of the place of gluing of the layers of the intestinal membranes using an adhesive related construct, have been determined. The potential difference between the electrodes and the duration of exposure of the gluing site for gluing the original intestinal raw materials: pork belly, lamb belly, beef belly were determined. At a potential difference of 100 V, the duration of exposure of the gluing site for pork and lamb bellies is 17 minutes, and for beef bellies − 20 minutes. It is noted that the results differ in the duration of exposure of the gluing site, which is probably due to the thickness of the layer of the raw material. The proposed technology would contribute to improving the efficiency of the technology of glued sausage casings from intestinal raw materials and could be used at enterprises for the processing of agricultural products and the meat processing industry
View
... Dora, Kumar, Van Goubergen, Molnar and Gellynck (2013) posits that lean manufacturing practices in food SMEs is still at its infancy in European food SMEs however it improves operational performance, mainly productivity and quality. In India lean manufacturing has significantly affected the competitiveness of the food and beverage industry (Kezia & Kumar, 2017). Taj and Morosan, (2011) indicated significant gaps in lean manufacturing practices among different industries in China, with the petroleum and hi-tech industries performing relatively best. ...
View
... In their analysis of the benefits of lean manufacturing processes in the food and beverage industry, Kezia, Kumar, and Sai (2017) state that lean manufacturing leads to minimum waste and maximum utilization of resources. ...
Reducing food waste through lean and sustainable operations: A case study from the poultry industry
Article
Full-text available
  • Sep 2021
The growing need for solving the problem of food waste for tackling the survival of the planet and humankind is encouraging researchers to seek sustainable operations that alter the conventional methods that are currently in use in the food industry. Lean thinking has been used in this study to propose sustainable operations that incorporate social, economic, and environmental aspects and to handle the multidisciplinary and complex nature of reducing food waste. The value stream mapping methodology has been employed to explain food waste and generate drivers and to observe the end-to-end system flow. Since most of the waste is observed in upstream operations in emerging economies, one of the biggest meat-processing companies in Turkey is studied for illustrating the proposed methodology. As a result of the model, lean and sustainable food operations are suggested considering social, economic and environmental aspects. KEYWORDS: Lean management; sustainability; food waste; value stream mapping; emerging economy
View
... Lean is used to eliminate all types of inefficiencies and activities that do not add value to the process, typically called waste. Lean principles have been successfully used in industry and services (Bhamu et al., 2013;Dentz et al., 2009;Grove et al., 2011;Hodge et al., 2011;De Jong and Beelaerts van Blokland, 2016;Gutierrez-Gutierrez, 2016;Mrugalska and Wyrwicka, 2017;Kezia et al., 2017;Yadav et al., 2018;Almutairi et al., 2019). Singh and Rathi (2019) present a review from 2000 to 2018 about the implementation of lean six sigma (LSS) in business organizations pointing out the relevance of LSS in reducing organizations waste, improving processes, while reducing costs rising the societal living standards. ...
Lean waste assessment in a laboratory for training chemical analysts for the pharmaceutical industry
Article
  • Jun 2021
Purpose The purpose of this paper is to make a lean assessment of a chemical analyst training laboratory in a higher education institution and identify the main types of waste on a daily basis and understand the lean maturity of the laboratory and establish priority areas of intervention to make the laboratory leanest. Design/methodology/approach A single descriptive case study methodology was used to carry out the lean laboratory evaluation. The lean manufacturing waste terminology was adapted to a lean analytical laboratory environment, and a lean waste assessment step-by-step procedure was developed to reach the study goal. Findings Three types of waste (i.e. transport, waiting and defects) were the main contributors of the problem. The Pareto analysis results showed that 37.5% of the different types of waste contributed to almost 51.4% of the problems. The case study allowed on diagnosing wastes, understanding the lean maturity in a teaching laboratory setting and priority areas of intervention Practical implications Some data collection methods were used, and tools were developed to answer the research questions. A waste measurement instrument was created to evaluate lean waste in a chemical analytical laboratory, and a lean classification scheme was built to understand the lean maturity of the laboratory. The lessons learnt of the lean assessment in a teaching laboratory and the developed tools will be helpful for future research and for practitioners in a teaching chemical analytical laboratory setting. Originality/value The number of lean assessment studies in teaching laboratories is not very significant, and this work contributes to overcome this gap illustrating the lean waste assessment foundation with a step-by-step procedure and tools used in a teaching laboratory to perform a lean assessment and identify opportunities for improvement. A generic roadmap to lean laboratory waste assessment and continuous improvement is proposed with the key elements to take into consideration.
View
Agglomeration and driving factors of regional innovation space based on intelligent manufacturing and green economy
Article
  • Feb 2021
The green upgrade of smart manufacturing enterprises is an important measure for China to take the road of comprehensive and coordinated development of economy and environment, and it is the main method for China to achieve smart manufacturing in China. carbon tariff barriers and technical barriers in domestic and foreign markets and the upgrading of domestic consumption. At the same time, it needs to comply with the government’s efforts. Research on supply-side reforms, improved product supply structures, and the need to improve product quality for transformation and upgrades, and green innovation is imminent. This paper focuses on the regional green innovation system of China, uses bibliometric analysis methods to systematically sort out the hot areas of green innovation research at this stage, and analyzes that the current research in the field of green innovation lacks in-depth research results on regional green innovation systems. The data in this article is collected by formulating scales and issuing questionnaires. The questionnaire is mainly divided into four parts: the basic information of traditional manufacturing enterprises, the driving factors of green innovation, the survey of green innovation and corporate performance. The experimental results show that the overall factors in environmental regulation drive regional green system coordinated innovation development with a P value less than 0.05, there is a big difference in this. Geographical proximity has a significant positive impact on the collaborative development of green innovation systems in China’s regions. Whether it is a technological driver, a market driver, or an environmental regulatory factor, it has a significant impact on the collaborative development of regional green innovation systems. Therefore, research into the drivers of green innovation and its impact on performance in traditional manufacturing companies has important theoretical and practical importance.
View
View
Lean Concepts and Methods : 3P
Article
Full-text available
  • Oct 2016
Nowadays competitive business environments, introduce new products of the global market, ahead of the competition and evaluate optimized procurement of goods from the global point of view, are essential. Accomplish businesses develop and strengthen their market position by manufacturing the highest quality of finish products more efficiently, at the minimum cost, and bringing them to market rapidly. Review the development step of a new product and need to start production preparation process (3P) based on Just-in-Time (JIT) within a small amount of time and in a timely fashion. Production Preparation Process 3P is an advanced lean approach required simulation, visual thinking, and kaizen for quick design for manufacturability. This work focuses on to minimize wastage of product, process design and used to eliminate waste in existing processes. However, this method is using within companies such as metals, petro- chemical, automobile industry and similar industries due to the demand for new products have increased. The reason for this research was to show the lean concepts, which can be efficient, effectively planned and managed.
View
Application of Lean Manufacturing Tools in the Food and Beverage Industries
Article
Full-text available
  • Oct 2015
Recent years have shown an increasing use of lean manufacturing (LM) principles and tools in several industrial sectors. Already a wellestablished management philosophy, it has shown numerous successful applications even outside production environments. This work presents the application of some LM tools, and the corresponding shift in philosophy, in two Portuguese companies of the food and beverage industries. Main implementation issues are presented and discussed; followed by the results obtained from the application of LM tools in the production system of these companies. Significant gains are obtained in both companies and, more importantly, it instills a continuous improvement culture and increases production flexibility while reducing lead times.
View
View
View
Implementation of Lean Principles in a Food Manufacturing Company
Conference Paper
  • Jun 2013
Lean is a powerful tool, which can bring significant benefit to manufacturing industries by creating value through reduction of waste. Although the lean concept has become very popular in mass production industries such as the automotive industry, more recently the concept has been adopted in different batch processing industries and service sectors. The application of lean tools into the food processing industry has not received the same level of attention compared to the traditional manufacturing industries. The paper focuses on implementation of lean tools in a food manufacturing company in UK. The company produces diverse ranges of meat-free and dairy-free food products such as vegetable burgers, sausages, cutlets etc., and supply to the major supermarket chains in UK. In general, the typical manufacturing cycle includes raw material preparation, cooking, mixing, forming into a desired shape, coating with a crumb mixture, and frying. Finally, the products are frozen and then packaged. First, lean tools and lean practices in food manufacturing industries have been briefly presented. The implementation of lean into the company started with reviewing the products, manufacturing processes, technical facilities, and process flow charts. Key areas have been identified to achieve tangible benefits by implementing lean tools such as waste elimination, 5S, single minute exchanges of dies (SMED), Andon system, visual management, work standardisation etc. The results have been presented in the form of a case study. The paper concludes that lean tools can be successfully implemented in a food manufacturing company to improve production efficiency, to improve product quality, and to reduce production cost by reducing waste and adding value. The information presented will be of interest to general food manufacturers and in particular to frozen food manufacturers.
View
Value stream management: Eight steps to planning, mapping, and sustaining lean improvements
  • Jan 2002
  • J Healthc Qual
  • 47
  • D Tapping
  • T Luyster
  • T Shuker
Tapping, D., Luyster, T., and Shuker, T, Value stream management: Eight steps to planning, mapping, and sustaining lean improvements, Journal for Healthcare Quality 25(6):47 · November 2003 (New York, NY: Productivity Press, 2002).
How to implement lean manufacturing (Tata Mcgrawhill
  • 133-145
  • Lonnie Wilson
Lonnie Wilson, How to implement lean manufacturing (Tata Mcgrawhill, Edition 2,9,10, 21-22) pp.133-145.
Waste Management and minimization
  • 154-169
  • . L Robert
  • Barbara Peacock
  • Steve Peach
  • Gibbs
Robert.L.Peacock, Barbara Peach, Steve Gibbs, Waste Management and minimization, ISBN: 978-1-84826-119-8, 1, pp.154-169.
Lean, Clean and Green Food Processing
  • Jun 2010
  • Glen Miller
  • Christian Paulson
Glen miller and Christian Paulson, Lean, Clean and Green Food Processing, Sustainable plant June, 2010.