Application of Lean Manufacturing to Enhance Production Efficiency a Case Study of Powder Milk Factory

This research aims to reduce the production time per piece in a powdered milk factory by studying the causes of bottlenecks and designing a new work process using Lean manufacturing concepts. The tools used in the research include Value Stream Mapping (VSM), Line balancing, Single Minute Exchange of Dies (SMED), and 5 Why Analysis. Qualitative research found that the factory reduced production time per piece by 70% after implementing Lean techniques. SMED helped minimize machine setup time by 84%, and 5 Why Analysis helped identify the root cause of the problem, leading to targeted solutions and the elimination of waste. This resulted in a 47% reduction in lead time and an 85% reduction in work-in-process. This research demonstrates that the Lean manufacturing concept can increase production capacity and reduce waste in a finished food factory. It can also be applied to other finished food processes.