An Initial lean waste assessment at a manufacturing plant: an attempt to prioritise waste elimination

Abstract

Lean is a management philosophy aimed at improving efficiency by eliminating all forms of Lean waste in the workplace. While lean practices are well-established in manufacturing, their application in sectors like printing remains significant. This study focuses on identifying and prioritizing critical Lean waste in a flexographic printing plant, a key area for operational improvement. Using a three-step approach, Waste Identification, Waste Assessment, and Root Cause Analysis, the study identifies defects and inventory as the most Critical lean waste types in the printing plant. Data was collected through Gemba walks, walkthrough surveys, interviews, and company records. The Waste Assessment Questionnaire (WAQ) and Waste Relationship Matrix (WRM) were used to prioritize lean wastes and analyze their interdependencies. Cause and Effect diagrams were used to uncover the root causes of defects, and a 5-Whys analysis was used to uncover the root causes of inventory. The findings provide actionable insights for reducing waste in the flexographic printing Plant, offering broader implications for cost reduction and efficiency in related sectors.