An Approach to Improve the Process Cycle Efficiency and Reduce the Lead Time of a Mango Juice Processing Line by Using Lean Tools: A Case Study

This study was a case analysis of the effective performance of lean tools adoption in a mango juice processing line-1 of X Food Industry in Bangladesh. This work addresses the implementation of lean tools in order to evaluate present Process Cycle Efficiency and lead time prior to develop an improved strategy to bring the improved PCE and to reduce the lead time. Value Steam Map and Pareto analysis were applied to evaluate the present and future state PCE and lead time. At the present state, the PCE was found 15.28% and after the implementation of lean tools it would be 34.05% at future state where lead time would also be reduced by 55.10%. The production flow was optimized by minimizing several non value added activities and time such as bottlenecking, machine breakdown, queue time, waiting time, material handling time, etc. Eventually, this case study will be useful in developing a more generic approach to design lean environment in management system of the studied X food industry.