Central European Business Review 2013, 2(2):31-44 | DOI: 10.18267/j.cebr.44
Optimum Resource Allocation and Eliminating Waste Inside the Food Industry
- 1 Chandru Nagarajan Sathiyabama, MSc., Sheffield Hallam University, United Kingdom, chandruscm88@gmail.com
- 2 Pramod Dasan, MBA, Faculty of International Relations, University of Economic, Prague Czech Republic, pramod.dasan@gmail.com
This article seeks to allocate optimum resources for the wrapping section and suggesting a suitable method that needs to be in place for successful elimination of waste inside the food industry's wrapping section. It also includes identifying the main reasons for various types of wastages inside the wrapping section and cost of all the wastages. The paper is based on observation and research using the approach of lean tools and techniques. The methodology used for evaluating data is value stream mapping and some statistical SPSS tools for analysis. Data are real and are gathered from three different production shifts inside a food industry wrapping section. The main reasons for wastages inside the wrapping section are highlighted. Finally, the paper was concluded by estimating total cost of wastages and recommending a suitable way to save wastage costs. The need to change the jaws inside the wrapping machines, regular maintenance of all machines throughout the industry and training of personnel are recommended. The possible methods along with their benefits to reduce waste, operators, improve productivity and business growth were also highlighted.
Keywords: LEAN Methodology; Optimization in Food Logistics; Operations in Food lndustry
JEL classification: C40, C41, C44, C81
Received: February 4, 2013; Revised: June 12, 2013; Published: June 30, 2013 Show citation
References
- Achanga, P., Shehab, E., Roy, R., Nelder, G. (2006). Critical Success factors for lean implementation within SMEs. Journal of Manufacturing Technology Management, 17 (4), 460-471.
Go to original source...
- Albert, M. (2004). Setup reduction: at the heart of lean manufacturing. Modern Machine Shop, 76 (7), 66-73.
- Angra, S., Sehgal, R., Samsudeen Noori, Z. (2008). Cellular Manufacturing - a time based analysis to the layout problem. International Journal of Production Economics, 112 (1), 427-438.
Go to original source...
- Barla, S. B. (2003). A case study of supplier selection for lean supply by using a mathematical model. Logistics Information Management, 16 (6), 451-459.
Go to original source...
- Bichino, J. (2000). The Lean Tool Box. 2 ed. Buckingham: Picsie Books.
- Bititci, U. S. et al. (2011). Managerial processes: business process that sustain performance. International Journal of Operations & Production Management, 3(8), 851-891.
Go to original source...
- Cequea, A. (2012). What are the Benefits of value Stream mapping?, (available at: http://www.ehow.com/list_6624878_benefits-value-stream-mapping_.html), [accessed 13 August 2012].
- Chen, J. C., Li, Y., Shady, B. D. (2010). From value stream mapping toward a lean/sigma continuous improvement process: an industrial case study. International Journal of Production Research, 48 (4), 1069-1086.
Go to original source...
- Chowdary, B. V., George, D. (2012). Improvement of manufacturing operations at a pharmaceutical company: A Lean Manufacturing approach. Journal of Manufacturing Technology Management, 23(1), pp. 56-75.
Go to original source...
- Dekker, H. C. (2003). Value chain analysis in interfirm relationships: a field study. Management Accounting Research, 13 (1), 1-23.
Go to original source...
- Eatock, J., Dixon, D., Young, T. (2009). An exploratory survey of current practice in the medical device industry. Journal of Manufacturing Technology Management, 20 (2), 218-234.
Go to original source...
- Evans, B., Simons, D. (2000). Lean delivery road map - how to make it happen. Logistics Focus, 2 (9), 30-39.
- Forrester, J. (1958). Industrial dynamics a major breakthrough for decision makers. Harvard Business Review, 36 (4), 37-66
- Frøkjaer, E., Hertzum. M., Hornbaek, K. (2000). Measuring usability: are effectiveness efficiency, and satisfaction really correlated? Proceedings of the CHI 2000 Conference on Human Factors in Computing Systems, 345-352.
- Haque, B. James-Moore, M. (2004). Applying lean thinking to new product introduction. Journal of Engineering Design, 15 (1), 1-31.
Go to original source...
- Hines, P., Rich, N. (1997). The seven value stream mapping tools. International Journal of Operations & Production Management, 17 (1), 46-64.
Go to original source...
- Hines, P., Holweg, M., Rich, N. (2004). Learning to evolve. International Journal of Production and Management, 24 (10), 914-1011.
Go to original source...
- Hkrita (2009). Value Stream Mapping: Development of a Problem Solving model for the Hong Kong Textiles and Clothing Industries, (available at: http://www.clothingtraining.org.hk/webpage/hkrita-psm/TrainingMaterials/Value%20Stream%20Mapping.pdf), [accessed 13 August 2012].
- Hunter, S. L., Black, J. T. (2007). Lean Manufacturing: a Cellular case study. Journal of Manufacturing Systems, 6 (2), 129-144.
Go to original source...
- Jones, D., Womack, J. (2000). Seeing the Whole. Boston: LEI.
- Kao, C. et al. (1995). Productivity improvement:efficiency approach vs effectiveness approach. International Journal of Management Science, 23 (2), 197-204.
Go to original source...
- Khamis, N. et al. (2009). Development of 5S practice checklist for manufacturing industry. World Congress on Engineering 2009 (Vol. 1), 545.
- Khatri, V. (2009). Benchmark 6ix sigma : Is Six Sigma Being Applied In Industry Or Specialization Of My Choice?, (available at: https://benchmarksixsigma.groupsite.com/post/the-benefits-limitations-of-lean-and-six-sigma), [accessed 13 August 2012].
- Lasa, I. S., Castro, R. D., Laburu, C. O. (2009). Extent of the use of Lean concepts proposed for a value stream mapping application. Production Planning and Control, 20 (1), 82-98.
Go to original source...
- Lian, Y. H., Van Landeghem, H. (2007). Analysing the effects of lean manufacturing using a value stream mapping-based simulation generator. International Journal of Production Research, 45 (13), 3037-3058.
Go to original source...
- Lummus, R. R., Vokurka, R. J., Rodeghiero, B. (2006). Improving Quality through value stream mapping :a case study of a physician's clinic. Total Quality Management and Business Excellence, 17 (8), 1063-1075.
Go to original source...
- Matt, D. T. (2008). Template based production system design. Journal of Manufacturing Technology Management, 19 (7), 783-797.
Go to original source...
- McDonald, T., Van Aken, E. M., Rentes, A. F. (2002). Utilising simulation to enhance value stream mapping:a manufacturing case application. International Journal of Logistics Research and Application:A Leading Journal of Supply Chain Management, 5 (2), 213-232.
Go to original source...
- Mentzer, J. T., Konrad, B. P. (1991). An efficiency effectiveness approach to logistics performance analysis. Journal of Business Logistics, 12 (1), 33-61.
- Monden, Y. (1993). Toyota Production System: An Integerated Approach to Just-in-Time. Norcoss,GA: Industrial Engineering and Management Press.
Go to original source...
- Nielsen, J., Levy, J. (1994). Measuring usability preference vs. performance. Communications of the ACM, 4, 66-75.
Go to original source...
- Ohno, T. (1988). Toyota Production System. Cambridge: Productivity Press.
Go to original source...
- Papadopoulou, T. C., Özbayrak, M. (2005). Leanness: experiences from the jouney to date. Journal of Manufacturing Technology Management, 16 (7), 784-807.
Go to original source...
- Porter, M. E. (1985). Competitive Advantage. NewYork: The Free Press.
- Rother, M., Shook, J. (1999). Learning to See: Value Stream Mapping to Create Value and Eliminate Muda. Brookline: The Lean Enterprise Institute.
- Serrano, I., Ochoa, C., Castro, R. (2008). Evaluation of value stream mapping in manufacturing system redesign. International Journal of Production Research, 46 (16), 4409-4430.
Go to original source...
- Seth, D., Gupta, V. (2005). Application of value stream mapping for lean operations and cycle time reduction: an Indian case study. Production Planning and Control: The Management of Operations, 16 (1), 44-59.
Go to original source...
- Sholihah, M. (2012). BPR, Prototyping Tool: Business Process Re-engineering, (available at: http://nikmatus-sholihah.mhs.narotama.ac.id/sia-2/tugas-individu-bpr-prototyping-case-tool), [accessed 5 September 2012].
- Simons, D. W., Francis, M., Bourlakis, M., Fearne, A. (2003). Identifying the determinants of value in the UK red meat industry. Journal on Chain and Network Science, 3 (2),109-121.
Go to original source...
- Slomp, J., Chowdary, B. V., Suresh, N. C. (2005). Design of virtual manufacturing cells: a mathematical programming approach. Robotics and Computer-Integrated Manufacturing, 21 (3), 273-288.
Go to original source...
- Taj, S. (2008). Lean Manufacturing performance in China: assessment of 65 manufacturing plants. Journal of Manufacturing Technology Management, 19 (2), 217-234.
Go to original source...
- Tapping, D., Luyster, T., Shuker. T. (2002). Value Stream Management. New York: Productivity Press.
Go to original source...
- Taylor, D. H. (2006). Strategic considerations in the development of lean agri-food-supply chains: a case study of the UK pork sector. Supply Chain Management: An International Journal, 11 (3), 271-280.
Go to original source...
- Towill, D. (1996). Industrial dynamics modelling of supply chains. The International Journal of Physical Distribution & Logistics Management, 25 (2), 23-43.
Go to original source...
- Vinodh, S., Arvind, K. R., Somanaathan, M. (2010). Application of value stream mapping in an Indian Camshaft Manufacturing Organization. Journal of Manufacturing Technology Management, 21 (7), 888-900.
Go to original source...
- Womack, J., Jones, D. T. (1996). Lean Thinking: Banish Waste and Create Wealth in Your Corporation. New York.: Simon & Schuster.
- Womack, J. P., Jones, D. T., Roos, D. (2007). The Machine That Changed The World. New York: The Free Press.
- Yang, T. M., Su, C. T. (2007). Application of Hoshin Kanri for productivity improvement in a semi conductor manufacturing company. Journal of Manufacturing Technology Management, 18 (6), 761-775.
Go to original source...
- Young, S. M., Shields, M. D., Wolf, G. (1988). Manufacturing controls and performance: an experiment. Accounting Organisations and Society, 13 (6), 607-618.
Go to original source...
- Yusuf, Y. Y., Adeleye, E. O. (2002). A comparitive study of lean and agile manufacturing with a related survey of current practices in the UK. International Journal of Production Research, 40 (17), 4545-4562.
Go to original source...
- Zokaei, A. K., Simons, D. W. (2006). Value Chain Analysis in Consumer focus improvement: A case study of the UK red meat imdustry. The International Journal of Logistics Management, 17 (2), 141-162.
Go to original source...
This is an open access article distributed under the terms of the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License (CC BY NC ND 4.0), which permits non-comercial use, distribution, and reproduction in any medium, provided the original publication is properly cited. No use, distribution or reproduction is permitted which does not comply with these terms.