Implementation of Lean Manufacturing Principles to Minimize Waste in the Fertilizer Production Process: Case Study of ABC Co., LTD

Abstract

This study aims to analyze the types and causes of waste occurring in the fertilizer production process of ABC Co., Ltd., and to propose process improvement strategies based on Lean Manufacturing principles to enhance efficiency and reduce operational costs. Data were collected through on-site observations and interviews with relevant personnel. The findings revealed several activities that contributed to waste within both the production line and the loading process.

A process analysis was conducted using a flow process chart to identify areas of inefficiency, guided by the concept of the seven types of waste. The ECRS principle—Eliminate, Combine, Rearrange, and Simplify—was then applied to improve workflow efficiency in alignment with Lean practices. As a result, the production capacity of the Bulk Blend Line increased from 163 to 168 bags per hour, with a reduction in production time and a noticeable decrease in labor cost per unit. In the loading process, the loading rate more than doubled, while labor cost was reduced significantly—from 281.25 to 93.75 baht per hour.

These findings demonstrate that the application of Lean Manufacturing principles can effectively reduce waste, improve operational performance, and lower labor costs, offering a practical direction for enhancing the competitiveness of the fertilizer industry in the long term.