A study on the adoption of lean management techniques: Case study in bakery industry

Mohd Zawawi, Nurafiqah (2019) A study on the adoption of lean management techniques: Case study in bakery industry. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Lean manufacturing system (LMS) has infiltrated the manufacturing sector around the world. Other than eliminating waste, the benefits of lean include resource utilization and value creation for end customers. The commonly used lean tools and techniques include kaizen, 5S and visual management. However, some companies have not fully utilized the lean tools and reap the benefits. The objectives of this study is to determine the implementation of lean techniques, to identify the challenges in the implementation of lean technique and to demonstrate a process improvement project via the project Plan, Do, Check, Act (PDCA). The study is conducted at the premise of a bakery in Melaka Tengah, Malacca. The research is conducted via observation and interview where researcher have used semi-structured interview involving four respondents comprising the owners and staff of the company. The findings showed that the lean techniques that are being employed by companies are 5S, Standard Operating Procedure (SOP), Standardized Time, Poka Yoke, Just in Time (JIT), and Visual Management. Factors such as top management support, employee training and education, communication, worker’s participation and organizational culture are factors that greatly affect the challenges in the company's lean implementation. In addition, the from the PDCA project, the company has managed to reduce the search time for equipment and materials from 10 min 4 sec to 5 min 25 sec. This is an improvement of 53.81%. 5S and visual management have been used in the PDCA. The research has shown that simple lean tools if properly utilized can produce great impact to the operation of the bakery business.

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