Investigating the Effectiveness of Lean Manufacturing Techniques in Reducing Waste and Improving Productivity: A Case Study of Godrej Food Ltd

Abstract

This study investigates the application of Lean Manufacturing techniques to enhance productivity and reduce waste at Godrej Food Ltd, a leading player in the poultry processing industry. The research focuses on evaluating current operational workflows in critical areas such as bird input, killing, evisceration, deboning, and packaging. Detailed process mapping and analysis were conducted to identify inefficiencies and bottlenecks affecting overall output. Based on Lean principles like 5S, Kaizen, Time Study, Work content calculation TAKT time calculation by using Maynard operation and Sequence technique to improved process flows were designed and compared with existing methods to determine their effectiveness. The findings reveal that significant improvements in productivity were achieved through reduced cycle times, better workstation organization, and streamlined movement of materials. The redesigned processes led to a noticeable decrease in waste caused by overprocessing, motion, waiting, and defects. Notably, changes in the killing and evisceration lines resulted in higher throughput and improved hygiene standards. By implementing Lean strategies, the company also minimized manual errors and increased consistency in operations. This case study demonstrates that adopting Lean Manufacturing principles can lead to substantial gains in efficiency and product quality in the food processing sector. The results serve as a valuable reference for similar industries aiming to improve performance through process optimization and waste reduction.