Though it originated in the auto manufacturing industry, lean principles can offer substantial benefits to food and beverage manufacturers. Here we’ll explore the core concepts of lean manufacturing and 10 ways applying them can improve operations in the food and beverage sector.
What is Lean Manufacturing?
Lean manufacturing is a production philosophy centered around maximizing value while minimizing waste. In essence, Lean Production seeks to deliver finished products just as the customer needs them, in the quantity required, without wasted time, effort, inventory, or defects.
Five Core Lean Principles
Practicing these five principles facilitates the flexible, waste-free manufacturing of goods matching precise market demand.
1.) Identify Value
First, gain a detailed understanding of what truly creates value for the end customer. This means examining each step in the production process to distinguish value-add activities from non-value activities, which are considered waste (or “muda” in Lean terminology). Determining value from the customer’s perspective steers all subsequent efforts to design and manage lean processes.
2.) Map the Value Stream
After identifying value, the next imperative is developing a value stream map – a visual representation tracing the flow of materials and information from raw material receipt to finished product delivery. Value stream mapping reveals opportunities to eliminate delays, quality problems, and sources of waste on the production line.
3.) Create Flow
Once waste is exposed and removed, the Lean focus shifts to designing smooth, continuous workflow processes where goods can be manufactured at the pull of the customer without interruption or idle time. Tools like production levelling, cellular manufacturing, and quick changeovers aid the transition from batch and queue processing to single-piece flow.
4.) Establish Pull
Rather than pushing output based on forecasts, Lean systems pull production according to real customer demand. Kanban signals and systems keep inventory levels lean while coordinating just-in-time movement of goods at every step, from suppliers to end customers.
5.) Seek Perfection
Pursuing the goal of perfect value creation inspires continuous improvement or “kaizen”. Instead of intermittent innovation projects, the Lean mindset engages all workers to contribute ideas and refine processes incrementally forever. This drive toward perfection removes waste while ultimately providing customers more value at lower cost.
Eliminating Waste with Lean
Common types of waste targeted by lean include: overproduction, waiting, unnecessary transport, over processing, excess inventory, unnecessary movement, and defects. By systematically identifying and eliminating waste through techniques like 5S, value stream mapping, standardized work, poka-yoke mistake proofing, and continuous improvement events, lean enables products to be manufactured faster, cheaper, and with higher quality.
Top 10 Lean Benefits for Food & Beverage
Applying Lean thinking to food and beverage operations can:
1.) Shorten Changeover Times
Tools like SMED enable faster line changeovers so different products can be made in smaller batches, increasing flexibility.
2.) Reduce Overproduction
Making only what is needed when it is needed averts waste, inventory carrying costs, and product deterioration.
3.) Improve Inventory Management
Supermarkets and consumers require just-in-time delivery with short code dates, making good inventory management essential.
4.) Decrease Defects
Mistake proofing production processes averts discarding defective products.
5.) Standardize Work Processes
Standardized work and procedures ensure consistency and efficiency.
6.) Shorten Lead Times
Mapping production flows with value stream mapping reveals opportunities to compress cycle times from raw ingredients to finished goods.
7.) Lower Production Costs
Eliminating waste cuts operating expenses.
8.) Develop Workforce Flexibility
Cross-training workers in multiple skills versus specialized roles allows people to switch tasks as needed.
9.) Continuously Improve Operations
Regular “kaizen” rapid improvement events unlock bottom-up innovations as teams solve problems and streamline processes.
10.) Enhance Food Safety
Lean tools can help reinforce compliance with hazard analysis protocols like HACCP plans.
Applying Lean for Competitive Advantage
The principles of lean manufacturing offer significant opportunities for food and beverage companies to improve their operations and bottom lines. As consumers increasingly demand affordability, quality, and responsibility from the products they buy, optimizing production flows, cutting waste, and creating flexible, standardized processes can provide a real competitive advantage. Rather than a niche manufacturing methodology, lean is a proven framework ready to help food and beverage producers compete in the 21st century landscape.
Examining end-to-end value streams with fresh eyes can reveal countless openings to implement lean techniques, allowing companies to trim costs while providing the safe, sustainable products today’s shoppers expect. Lean thinking offers a path toward efficient, responsive manufacturing able to get wholesome offerings to market faster than ever.
with contributions from Michael Silungan, Senior Recruiter at Planet Forward
Photo Credit: Canva