The optimization of the production process using "The Value Stream Mapping: case study GIPLAIT-ARIB "Pasteurized and Conditioned Milk "

Abstract

This study focuses on optimizing pasteurized milk production at GIPLAIT-ARIB using Value Stream Mapping (VSM), a key Lean Manufacturing tool. The main objective is to identify and eliminate waste to enhance operational efficiency and customer satisfaction. A qualitative approach was employed, combining field observations, interviews with production, quality, and maintenance managers, and analysis of technical data such as cycle times and defect rates. The results revealed several significant sources of waste. These included daily 30-minute downtime due to batch changeovers, overproduction representing 15% of batches exceeding customer demand, and packaging defects affecting 5% of milk bags, leading to substantial losses. Through VSM analysis, concrete improvements were achieved: a 20% reduction in cycle time (from 10,552 to 8,442 seconds per batch), a 12% decrease in intermediate inventory through FIFO system optimization, and the elimination of unnecessary operator movements using 5S methodology. In conclusion, this research demonstrates the effectiveness of VSM for optimizing industrial processes in the dairy sector. The proposed solutions, such as staff training and workstation redesign show measurable productivity gains. These improvements could be extended to other production lines to strengthen GIPLAIT-ARIB's competitiveness.