Lean Manufacturing in food production: Systematic review, bibliometric analysis and proposed application

Authors

DOI:

https://doi.org/10.17268/sci.agropecu.2024.042

Keywords:

management, enterprises, production, efficiency, foods

Abstract

In a changing environment, efficiency and adaptability are essential to improve business competitiveness. The present study analyzed the application of Lean Manufacturing in food production through a review of the scientific literature based in Scopus, using the PRISMA methodology and the Vosviewer and Bibliometrix software. From the bibliometric analysis, there is evidence of an increase in research on Lean Manufacturing in food companies since 2019, with an annual growth rate of 5.96%. Brazil and Peru stand out for their high scientific production, while Brazil and Belgium stand out in terms of citations. In addition, outstanding scientific collaboration between authors from South America and Asia is observed. Three relevant clusters were identified: principles, implementation tools and practical applications of Lean Manufacturing. The thematic mapping highlighted the concepts Cost Reduction, Process Monitoring, Six Sigma and Value Stream Mapping as the most prominent topics underlining the interest and applications in the scientific literature. The implementation of Lean Manufacturing in seven steps is proposed, facilitating the use of agile tools for process optimization and waste reduction in food companies. Lean Manufacturing contributes to improve the flow of products in the supply chain and to the sustainability of small and medium enterprises. Future research should focus on adapting Lean Manufacturing to various contexts and business models in the agri-food sector.

References

Abd Rahman, M. S., Mohamad, E., & Abdul Rahman, A. A. (2020). Enhancement of overall equipment effectiveness (OEE) data by using simulation as decision making tools for line balancing. Indonesian Journal of Electrical Engineering and Computer Science, 18(2), 1040. https://doi.org/10.11591/ijeecs.v18.i2.pp1040-1047

Ahmad, R., Amin, R. F. M., & Mustafa, S. A. (2022). Value stream mapping with lean thinking model for effective non-value added identification, evaluation and solution processes. Operations Management Research, 15(3-4), 1490-1509. https://doi.org/10.1007/s12063-022-00265-9

Apaza, N. M. C. (2021). Implementación de la metodología TPM-Lean Manufacturing para mejorar la eficiencia general de los equipos (OEE) en la producción de repuestos en una empresa metalmecánica. Industrial Data, 24(1), Article 1. https://doi.org/10.15381/idata.v24i1.18402

Aytekin, A., Okoth, B. O., Korucuk, S., Mishra, A. R., Memiş, S., Karamaşa, Ç., & Tirkolaee, E. B. (2023). Critical success factors of lean six sigma to select the most ideal critical business process using q-ROF CRITIC-ARAS technique: Case study of food business. Expert Systems with Applications, 224, 120057. https://doi.org/10.1016/j.eswa.2023.120057

Baca-Nomberto, A., Urquizo-Cabala, M., Ramos, E., & Sotelo-Raffo, F. (2021). A Model Utilizing Green Lean in Rice Crop Supply Chain: An Investigation in Piura, Perú. En T. Ahram, R. Taiar, K. Langlois, & A. Choplin (Eds.), Human Interaction, Emerging Technologies and Future Applications III (pp. 474-480). Springer International Publishing. https://doi.org/10.1007/978-3-030-55307-4_72

Bacon, C. M., Sundstrom, W. A., Stewart, I. T., & Beezer, D. (2017). Vulnerability to Cumulative Hazards: Coping with the Coffee Leaf Rust Outbreak, Drought, and Food Insecurity in Nicaragua. World Development, 93, 136-152. https://doi.org/10.1016/j.worlddev.2016.12.025

Bag, S., Rahman, M. S., Sharma, J., Chiarini, A., Srivastava, S. K., & Gupta, S. (2024). Building digital technology and innovative lean management capabilities for enhancing operational performance: An empirical study. Production Planning & Control, 1-20. https://doi.org/10.1080/09537287.2024.2327344

Bancovich Erquínigo, A., Ortiz Porras, J., Quintana Saavedra, H., Crispin Chamorro, P., Manrique Alva, R., & Vilca Carhuapuma, P. (2023). Green lean method to identify ecological waste in a nectar factory. International Journal of Production Management and Engineering, 11(2), 197-207. https://doi.org/10.4995/ijpme.2023.19598

Braglia, M., Gallo, M., & Marrazzini, L. (2021). A lean approach to address material losses: Materials cost deployment (MaCD). The International Journal of Advanced Manufacturing Technology, 113(1-2), 565-584. https://doi.org/10.1007/s00170-021-06632-3

Bučko, M., Krejčí, L., Hlavatý, I., & Lorenčík, J. (2024). Design and Optimization of Production Line Layout Using Material Flows. Machines, 12(3), 189. https://doi.org/10.3390/machines12030189

Cabrera, J., Corpus, O., Maradiegue, F., & Merino, J. C. A. (2020). Improving quality by implementing Lean Manufacturing, Spc, And Haccp In The Food Industry: A Case Study. South African Journal of Industrial Engineering, 31(4). https://doi.org/10.7166/31-4-2363

Caldera, H. T. S., Desha, C., & Dawes, L. (2017). Exploring the role of lean thinking in sustainable business practice: A systematic literature review. Journal of Cleaner Production, 167, 1546-1565. https://doi.org/10.1016/j.jclepro.2017.05.126

Castro, M. D. R. Q., & Posada, J. G. A. (2019). Implementation of lean manufacturing techniques in the bakery industry in Medellin. Gestão & Produção, 26(2), e2505. https://doi.org/10.1590/0104-530x-2505-19

Contreras Castañeda, E. D., Gordillo Galeano, J. J., & Olaya Rodríguez, K. J. (2024). Lean-Kaizen startup in panela production processes: The case of a trapiche. Cogent Engineering, 11(1), 2322834. https://doi.org/10.1080/23311916.2024.2322834

Costa, L. B. M., Godinho Filho, M., Fredendall, L. D., & Devós Ganga, G. M. (2021). Lean six sigma in the food industry: Construct development and measurement validation. International Journal of Production Economics, 231, 107843. https://doi.org/10.1016/j.ijpe.2020.107843

Cuggia-Jim&eacute, C., nez, Orozco-Acosta, E., & Mendoza-Galvis, D. (2020). Manufactura esbelta: Una revisión sistemática en la industria de alimentos. Informacion Tecnologica, 31(5), 163-172.

Das, K. (2019). Integrating Lean, Green, and Resilience Criteria in a Sustainable Food Supply Chain Planning Model. International Journal of Mathematical, Engineering and Management Sciences, 4(2), 259-275. https://doi.org/10.33889/IJMEMS.2019.4.2-022

Dieste, M., Panizzolo, R., & Garza-Reyes, J. A. (2020). Evaluating the impact of lean practices on environmental performance: Evidences from five manufacturing companies. Production Planning & Control, 31(9), 739-756. https://doi.org/10.1080/09537287.2019.1681535

Iranmanesh, M., Zailani, S., Hyun, S. S., Ali, M. H., & Kim, K. (2019). Impact of Lean Manufacturing Practices on Firms’ Sustainable Performance: Lean Culture as a Moderator. Sustainability, 11(4), Article 4. https://doi.org/10.3390/su11041112

Lagarda-Leyva, E. A. (2021). System Dynamics and Lean Approach: Development of a Technological Solution in a Regional Product Packaging Company. Applied Sciences, 11(17), 7938. https://doi.org/10.3390/app11177938

Liu, Q., Yang, H., & Xin, Y. (2020). Applying value stream mapping in an unbalanced production line: A case study of a Chinese food processing enterprise. Quality Engineering, 32(1), 111-123. https://doi.org/10.1080/08982112.2019.1637526

Marinelli, M., Deshmukh, A., Janardhanan, M., & Nielsen, I. (2021). Lean manufacturing and Industry 4.0 combinative application: Practices and perceived benefits. IFAC-PapersOnLine, 54(1), 288–293. https://doi.org/https://doi.org/10.1016/j.ifacol.2021.08.034

Martins, A. D. O., Dos Anjos, F. E. V., & Da Silva, D. O. (2023). The Lean Farm: Application of Tools and Concepts of Lean Manufacturing in Agro-Pastoral Crops. Sustainability, 15(3), 2597. https://doi.org/10.3390/su15032597

Melin, M., & Barth, H. (2018). Lean in Swedish agriculture: Strategic and operational perspectives. Production Planning & Control, 29(10), 845-855. https://doi.org/10.1080/09537287.2018.1479784

Milewski, D. (2022). Managerial and Economical Aspects of the Just-In-Time System “Lean Management in the Time of Pandemic”. Sustainability, 14(3), 1204. https://doi.org/10.3390/su14031204

Millones, C. A.-T., Quiroz-Flores, J. C., & S, N. (2023). Enhancement of Productivity and Efficiency through a Service Model with Lean Service Tools—Case Study. International Journal of Mechanical Engineering, 10(9), 18-30. https://doi.org/10.14445/23488360/IJME-V10I9P102

Molnar, V., & Tumik, A. (2018). Making Unit Cost in Production Process More Accurate – the Role of Queueing. International Journal of Engineering & Technology, 7(2.23), 129. https://doi.org/10.14419/ijet.v7i2.23.11899

Ortiz Porras, J. E., Bancovich Erquínigo, A. M., Candia Chávez, T. C., Huayanay Palma, L. M., Moore Torres, R. K., & Tinoco Gomez, O. R. (2023). Green Lean Six Sigma model for waste reduction of raw material in a nectar manufacturing company of Lima, Peru. Journal of Industrial Engineering and Management, 16(2), 169. https://doi.org/10.3926/jiem.4916

Orynycz, O., Tucki, K., & Prystasz, M. (2020). Implementation of Lean Management as a Tool for Decrease of Energy Consumption and CO2 Emissions in the Fast Food Restaurant. Energies, 13(5), 1184. https://doi.org/10.3390/en13051184

Ramlan, R., Ahmad, A. N. A., Omar, S. S., & Suhaimi, A. H. (2017). Continuous Improvement with Value Stream Mapping (VSM): A Case Study in SME Food Processing Industry. Advanced Science Letters, 23(1), 674-678. https://doi.org/10.1166/asl.2017.7295

Ribeiro, M. A. S., Santos, A. C. O., De Amorim, G. D. F., De Oliveira, C. H., Da Silva Braga, R. A., & Netto, R. S. (2022). Analysis of the Implementation of the Single Minute Exchange of Die Methodology in an Agroindustry through Action Research. Machines, 10(5), 287. https://doi.org/10.3390/machines10050287

Salah, S., & Mustafa, A. (2021). Integration of Energy Saving with Lean Production in a Food Processing Company. Journal of Machine Engineering, 21(4), 118-133. https://doi.org/10.36897/jme/142394

Satolo, E. G., Hiraga, L. E. D. S., Goes, G. A., & Lourenzani, W. L. (2017). Lean production in agribusiness organizations: Multiple case studies in a developing country. International Journal of Lean Six Sigma, 8(3), 335-358. https://doi.org/10.1108/IJLSS-03-2016-0012

Sharma, J., Tyagi, M., Panchal, D., & Singh, R. P. (2022). Contemplation of food industry attributes confronted in smooth adoption of Lean Six Sigma practices. International Journal of Six Sigma and Competitive Advantage, 14(1), 32. https://doi.org/10.1504/IJSSCA.2022.124294

Srimathi, R., & Hemamalini, S. (2022). Performance Analysis of Single-Stage LED Buck Driver Topologies for Low-Voltage DC Distribution Systems. IETE Journal of Research, 68(3), 1943-1955. https://doi.org/10.1080/03772063.2019.1682072

Tomás-Górriz, V., & Tomás-Casterá, V. (2018). La Bibliometría en la evaluación de la actividad científica. Hospital a Domicilio, 2(4), Article 4. https://doi.org/10.22585/hospdomic.v2i4.51

Ul Haq, I., Colwill, J. A., Backhouse, C., & Franceschini, F. (2022). Effects of lean distributed manufacturing on factory’s resilience: The current practice in UK food manufacturing sector. International Journal of Lean Six Sigma, 13(5), 1104-1136. https://doi.org/10.1108/IJLSS-07-2021-0124

Utama, D. M., & Abirfatin, M. (2023). Sustainable Lean Six-sigma: A new framework for improve sustainable manufacturing performance. Cleaner Engineering and Technology, 17, 100700. https://doi.org/10.1016/j.clet.2023.100700

Viles, E., Santos, J., Muñoz-Villamizar, A., Grau, P., & Fernández-Arévalo, T. (2021). Lean–Green Improvement Opportunities for Sustainable Manufacturing Using Water Telemetry in Agri-Food Industry. Sustainability, 13(4), 2240. https://doi.org/10.3390/su13042240

Wesana, J., De Steur, H., Dora, M. K., Mutenyo, E., Muyama, L., & Gellynck, X. (2018). Towards nutrition sensitive agriculture. Actor readiness to reduce food and nutrient losses or wastes along the dairy value chain in Uganda. Journal of Cleaner Production, 182, 46-56. https://doi.org/10.1016/j.jclepro.2018.02.021

Published

2024-10-22

How to Cite

Ferrer-Blas, R. I. ., Galarcep-Barba, I. ., & Solano-Gaviño, J. C. . (2024). Lean Manufacturing in food production: Systematic review, bibliometric analysis and proposed application. Scientia Agropecuaria, 15(4), 569-579. https://doi.org/10.17268/sci.agropecu.2024.042

Issue

Section

Original Articles