Optimizing Supply Chain and Manufacturing Efficiency through Lean Principles

This study explores the application of Lean Manufacturing and Lean Supply Chain principles to optimize production and supply chain efficiency at Laprima Plastics. Manufacturing inefficiencies—such as high defect rates, excessive inventory, unoptimized material flow, machine downtime, and high energy consumption—pose significant challenges to operational performance. The research adopts a structured methodology involving current state analysis through Product Flow Diagrams and Value Stream Mapping (VSM), root cause identification using DMAIC, Pareto Analysis, and Cause-and-Effect Diagrams, and the implementation of Lean tools such as 5S, Kaizen, inventory optimization, and internal logistics improvements. Key performance indicators (KPIs) are employed to measure improvements in defect rates, lead times, energy consumption, and overall production efficiency. The study expects to achieve a notable reduction in non-value-added activities, downtime, and energy waste, alongside improvements in inventory management and workplace organization. By integrating Lean strategies within the broader context of Industry 4.0, this research provides practical insights into sustainable manufacturing practices. The findings contribute to advancing cost-effective, environmentally conscious, and resilient production systems, offering a replicable model for other manufacturing organizations seeking operational excellence through Lean transformations.