A case study of vsm and smed in the food processing industry

Miguel Malek Maalouf*, Magdalena Zaduminska

*Corresponding author for this work

Research output: Contribution to journalJournal articleResearchpeer-review

Abstract

The relatively limited application of lean in the food process industries has been attributed to the unique characteristics of the food sector i.e. short shelf-life, heterogeneous raw materials, and seasonality. Moreover, barriers such as large and inflexible machinery, long setup time, and resource complexity, has limited the implementation and impact of lean practices in process industries in general. Contrary to the expectations in the literature, we bring in this paper a successful experience of lean implementation in a company of the food-processing sector. By focusing on two lean tools (VSM and SMED), the company reduced changeover time by 34%, and increased the production capacity of the main production line by 11%. This improvement enabled the company to avoid the use of temporary workers by extending the worktime of its workforce during peak months. Moreover, the reduction of setup time avoided the use of large lot size in production, which, in turn, reduced the total cycle time of production and the incidence of quality problems.

Original languageEnglish
JournalManagement and Production Engineering Review
Volume10
Issue number2
Pages (from-to)60-68
Number of pages9
ISSN2080-8208
DOIs
Publication statusPublished - Jun 2019
Externally publishedYes

Fingerprint

Food processing industry
Process industry
Setup times
Shelf life
Machinery
Resources
Food sector
Production capacity
Temporary workers
Food processing
Seasonality
Raw materials
Workforce
Lot size
Cycle time
Food
Production line

Keywords

  • Changeover
  • Food industry
  • Lean
  • Process industry
  • Value stream mapping

Cite this

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title = "A case study of vsm and smed in the food processing industry",
abstract = "The relatively limited application of lean in the food process industries has been attributed to the unique characteristics of the food sector i.e. short shelf-life, heterogeneous raw materials, and seasonality. Moreover, barriers such as large and inflexible machinery, long setup time, and resource complexity, has limited the implementation and impact of lean practices in process industries in general. Contrary to the expectations in the literature, we bring in this paper a successful experience of lean implementation in a company of the food-processing sector. By focusing on two lean tools (VSM and SMED), the company reduced changeover time by 34{\%}, and increased the production capacity of the main production line by 11{\%}. This improvement enabled the company to avoid the use of temporary workers by extending the worktime of its workforce during peak months. Moreover, the reduction of setup time avoided the use of large lot size in production, which, in turn, reduced the total cycle time of production and the incidence of quality problems.",
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A case study of vsm and smed in the food processing industry. / Maalouf, Miguel Malek; Zaduminska, Magdalena.

In: Management and Production Engineering Review, Vol. 10, No. 2, 06.2019, p. 60-68.

Research output: Contribution to journalJournal articleResearchpeer-review

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