Lean Manufacturing Implementation in a Frozen Corn Packaging Line: Bottleneck Elimination and Waste Reduction

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This thesis investigated the frozen corn packaging process using Lean manufacturing principles with the objective of identifying inefficiencies and improving overall process performance. A current-state value stream map was developed based on Gemba observations, revealing significant wastes related to transport, waiting, excess inventory, and manual inspection. Based on the analysis, a future-state process was proposed, including layout integration of tote preparation and packaging, automation at the feeding station, and an upgraded camera system. These improvements enabled the elimination of forklift transport, manual inspection, and FIFO conveyor buffers, resulting in a significantly simplified and more stable process flow. The results demonstrate that targeted Lean interventions supported by automation can substantially improve flow efficiency, reduce labour dependency, and enhance overall process performance.

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Lean Manufacturing, Frozen Corn Packaging Area, Waste Reduction, Bottleneck Elimination
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