Production Process Improvement Using Lean Principles and a Production Monitoring System in a Beverage Bottling Plant: A Case Study
Keywords:
Lean principles, Deming cycle, Performance dashboard, Breakdown timeAbstract
This study aims to analyze and improve the production process of a beverage bottling plant by applying Lean principles in conjunction with the development of an integrated performance dashboard to reduce machine breakdown time. The improvement approach is based on the Deming cycle and employs Lean tools such as preventive maintenance 5S and standard work to identify and eliminate waste in the production process. Pareto analysis indicates that the most critical wastes affecting the process are defects and rework, followed by waiting time. These findings correlate with the breakdown analysis, which identifies the Crowner and Carton Sealer machines as critical bottlenecks with the highest accumulated downtime, together accounting for 44.58% of the total breakdown time. Root cause analysis using the Why–Why technique reveals that the primary issues stem from a lack of preventive maintenance, the absence of standardized work procedures, and operator behaviors. After implementing the Improvement measures, the breakdown time of the Crowner machine decreased by 94% from 0.82% to 0.047%, while that of the Carton Sealer machine decreased by 76% from 0.76% to 0.175%. The results demonstrate that integrating Lean principles with the Deming cycle and a production performance dashboard can effectively reduce breakdown time, enhance production efficiency, and establish a sustainable system of continuous improvement.
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