The Impact of Lean Manufacturing on Reducing Waste and Improving Productivity: An Applied Study of a Food Processing Company in Salah al-Din Governorate

Abstract

The study aimed to demonstrate the impact of Lean Manufacturing on reducing waste and improving productivity at a food processing company in Salah al-Din Governorate, in light of the challenges facing the production process, including waste of materials and time, long waiting and downtime periods, the occurrence of defects, and the need for rework—all of which lead to higher costs and lower resource efficiency. The study adopted a descriptive-analytical approach due to its suitability for the nature and objectives of the study, and its sample consisted of employees in the production, technical, administrative, and supervisory departments who are involved in the production process. To achieve the study’s objectives, a questionnaire was used as the primary data collection tool, which assessed lean manufacturing practices and their role in reducing waste and improving productivity. Lean manufacturing practices included: continuous improvement, just-in-time production, total productive maintenance, and workplace organization (S5), while the dependent variables were waste reduction and productivity improvement. Appropriate statistical methods were also used to analyze the data and test the study’s hypotheses, most notably descriptive statistics, Cronbach’s alpha, and correlation and regression analysis. The results showed a statistically significant effect of lean manufacturing on reducing waste and improving productivity, as well as a statistically significant effect of reducing waste on improving productivity. The study concluded that adopting agile manufacturing practices contributes to increasing the efficiency of production operations through the optimal use of resources and the reduction of activities that do not add value. It recommended the integrated implementation of lean manufacturing, the promotion of continuous improvement, the development of total productive maintenance, workplace organization, and improved materials and inventory management, along with training employees and involving them in efforts to reduce waste and improve productivity.