Lean manufacturing and operational performance of Mumias sugar company limited, Kenya

Abstract

Lean manufacturing focuses on creating more value for customers by eliminating activities that are considered waste. This study sought to determine the effect of lean manufacturing practices on operational performance of Mumias Sugar Company Limited, Kenya. The research methodology adopted was a descriptive case study using Mumias Sugar Company Limited as the unit of study. Data was collected by use of an interview guide and was analyzed by use of content analysis. The research findings revealed that Mumias Sugar Company Limited has averagely implemented lean manufacturing practices. The effect of lean manufacturing on operational performance was cited as being positive. There has been reduction of waste and improved quality in operations due to standardization of processes. The main driver of lean manufacturing is cited as the need to improve factory time efficiency. Benefits derived from implementation of lean include: improved housekeeping of plant, improved efficiencies and standardization of processes. The major challenge that faces Mumias Sugar Company Limited is lack of management support and resistant to culture change. In conclusion, Mumias sugar company ltd has not strictly adhered to the application of lean management practices and therefore not enjoying its full benefits. Based on the findings of the study it is recommended that Mumias Sugar Company limited adopts full implementation of lean manufacturing practices to realize the full benefits of lean manufacturing. These findings should also help in encouraging the widespread adoption of lean manufacturing practices in the Kenya Sugar Industry. It is recommended that more research be done not only in the Kenya sugar industry but in Kenya. Future researches should try to evaluate Lean management approach to business management in the Kenya sugar industry