Optimizing Operations: Implementing Lean in Small-Scale Manufacturing Environment

Abstract

Beginning with a brief history of lean, the research explores lean principles and the array of tools and techniques associated with lean methodology. It reviews challenges and critiques of lean and existing literature on lean implementation in small and medium-sized enterprises (SMEs). The practical part of this study explores the implementation of lean principles in a small organization, Distran, focusing on optimizing its packaging process. It began by understanding the process and customer requirements using a SIPOC diagram and customer interviews. A detailed value stream map (VSM) and process map were then developed and presented to top management. Collaboratively, an improved process concept was formulated, and the future process was mapped out and then implemented. Stakeholder feedback and observations during the change implementation highlighted successful adaptation. Overall, the study demonstrates the feasibility and benefits of lean implementation in small organizations, showcasing significant process improvements and waste reduction.