THE IMPROVEMENT OF THE NON-VALUE-ADDED ACTIVITIES IN THE 3-IN-1 INSTANT FOOD PRODUCTION PROCESS BY APPLYING LEAN TOOLS

Abstract

This research represents one of the first large-scale, automatic process control system empirical efforts to systematically investigate and apply the Lean manufacturing methodology. The Lean tools can help to define, measure, and analyze the problem in this research. This study aimed to eliminate the waste, which causes the multiple steps from material handling to the production process by analyzing and identifying the root causes. After the simulation model was developed, the author compared the As-Is and To-Be outcomes, which are significantly different. The conclusion of this study showed that the total cycle time of the whole process is reduced from 70 minutes to 36 minutes and the batch size of work-in-process was also increased from 360 kg to 500 kg per cycle. Overall efficiency is seen to have increased in all processes where Lean principles have been carefully selected and applied.