ANALYZING THE MANUFACTURING PROCESS IN THE PERSPECTIVES OF LEAN PRODUCTION: A CASE IN GEOSYNTHETICS INDUSTRIAL WORKS PLC

Abstract

This study was conducted with the objective of analyzing GIW’s effort for ensuring success, by focusing on waste elimination and cost reduction in continuous improvement model. It makes use of both descriptive and explanatory research designs with detailed survey questionnaire in order to determine the different lean wastes, to determine the lean principles that are in use to eliminate the wastes, to analyze the association between waste elimination and cost reduction effort and to assess the relationship between continuous improvement and quality management system (the change management tool which the company implemented). The analysis of the data collected from survey questioner revealed that the company process has been tempted by wastes or muda of waiting, muda of re-workable materials inventory and muda of correcting defectives. The analysis also depicted another two major findings: the company’s cost reduction effort is negatively affected by muda of waiting and the implemented quality management system helps the company to ensure continuous improvement in its production process. The findings are evidence that identifying and eliminating lean wastes are the paramount in reducing production costs and ensuring success by winning the competitions. Therefore, the company management is recommended to make the successful implementation of lean production system as part of the long term strategic direction and policy of the company.