EVALUATION OF MANUFACTURING WASTES AND THEIR IMPACT ON OPERATIONAL PERFORMANCES: THE CASE OF BOTTLED WATER MANUFACTURING COMPANY

Abstract

Lean is a system all about the reduction of wastes which are significantly contributing to the ineffectiveness and inefficiency of the business entities if not systematically studied, analysed and long term solutions are taken. Waste could come in many different forms. Companies that have not previously been exposed to lean manufacturing tend to have a lot of wastes in their manufacturing processes. The case company, which is a bottled water manufacturer on which this research dealt with was not an exception. This research was conducted to identify the significance of the eight manufacturing wastes and their impact on operational performances of the case company, such as, on quality, delivery time and costs. To validate data through cross verifications, a triangulated measurement systems were employed including survey questionnaire, archival data collection and focus group discussions. To investigate the magnitude of wastes in processes, the research was conducted in two categories. Category 1 was representing the manufacturing and associated processes and category 2 the support process. A total of ninety five (95) responses were collected and the analysis of data demonstrated significant results on manufacturing wastes. Analysis made on the archival data collected in a period of twelve months has also revealed that significant amount of wastes were existing in the case company in different forms. The third instrument used was focus group discussions. It was designed to identify the root causes of manufacturing wastes and determine their significance to pose risks to the case company. The results obtained were also remarkable in that root causes were multidimensional and significant. The data analysis and conclusions made on these triangulated methods have shown consistency in that wastes were significantly present in both manufacturing and support processes and these wastes were also significantly negatively impacting on the operational performances of the case company. With these significant wastes, it will be very difficult for the case company to ensure business success in a sustainable manner. The researcher, therefore, has proposed short-term and long term solutions that will significantly reduce the eight manufacturing wastes and consequently improve operational performances.