Analysis of Factors Causing Wastes in FMCG Using Lean Tools

Abstract

In this research paper, we have used lean tools that are applicable in various faster growing industries like FMCG, pharmaceuticals; hospitality, manufacturing etc are used. The tool that is given the priority over others in identifying the waste is Value stream mapping. Value stream mapping is a lean tool that is used to translate both information and flow of data through which those processes that are not adding any positive value in our study can be easily eliminated. This paper is an effective effort to find out the waste production during manufacturing of a perishable goods in discrete manufacturing system. Pareto chart has been used to categories the factors that are responsible for the 80 percent of waste. Here Ishikawa diagram has played a vital role for finding of their possible causes and effect. Other contemporary lean tools like Kanban, Kaizen, and FIFO are used for future state map processing. The result obtained through the future state value stream map states the changeover time of various processes, the cycle time near to the takt time, improvement in lead time and total cycle time of the manufacturing process