The Effect of Lean Manufacturing Tools on Waste Reduction at Arjo Didessa Sugar Factory

Abstract

This study has main objective of assessment on the effects of lean manufacturing tools on waste reduction on Arjo Didesssa Sugar factory. The specific objectives of the study are from the perspective of Total productive maintenance, Mistake proofing, workplace organization (5S), continuous quality improvement and worker involvement. The research design for this study is explanatory, while the research approach is mixed approach. The target populations for this study are teams in the department of factory operation, department of kaizen and quality control. Both probability and non-probability sampling techniques are used and 208 samples selected. 188 questionnaires were completely filled and returned.  Both primary data and secondary data were used to fulfill the research objective. Quantitative part of data was analyzed by using SPSS version 20. The result of the study indicates that lean manufacturing tools are not implemented effectively therefore production waste is evident. Total productive maintenance, mistake proofing, worker involvement and continuous quality improvement have positive and significant effect on waste reduction.  Secondary data shows there is production waste in the factory but wastes are continuously reducing. Based on the evidence from questionnaire and secondary data it was concluded that lean manufacturing tools were not performed in excellent manner as result production wastes were evident in the factory. The researcher recommends based on the research findings and if lean manufacturing tools are performed in excellent manner by improving maintenance, training,  preventive and control devices for mistake proofing, Plan do check act cycle  and enhancing the skills of employees the factory they can reduce production wastes. Finally the researcher suggested for future research to be conducted by including other lean manufacturing tools to reduce production waste.

Keywords: Lean Manufacturing, total productive maintenance, workplace organization (5s), mistake proofing, workers involvement, continuous quality improvement