THE IMPACT OF LEAN MANUFACTURING TECHNIQUES ON WASTE REDUCTION IN GUINNESS NIGERIAN PLC

Abstract

Lean management has emerged as a transformative methodology for optimizing organizational operations through waste reduction and efficiency improvement. This study analyzes the implementation of lean practices at Guinness Nigeria Plc, focusing on key metrics such as Just-In-Time (JIT) production, continuous improvement (Kaizen), reduction in waiting time, and defect minimization. Using a mixed-methods approach, the study evaluates primary and secondary data, supported by statistical analysis to assess the significance of lean practices on operational performance. The findings indicate that JIT significantly reduces overproduction and inventory waste (p < 0.05), while continuous improvement initiatives enhance product quality by systematically addressing production inefficiencies (p < 0.01). However, challenges persist in managing waiting times and defect rates, which are statistically significant but show weaker correlations to overall efficiency improvements (p = 0.07). These results underscore the need for targeted interventions, such as advanced process monitoring and employee training, to address these issues. By integrating lean management more effectively, Guinness Nigeria Plc can achieve enhanced operational efficiency, reduced costs, and improved competitiveness in the brewing industry. This research provides actionable insights for similar organizations seeking to adopt lean practices in dynamic markets.