PET FOOD INDUSTRY APPLICATION OF LEAN AND ECRS TECHNIQUES TO IMPROVE PROTEIN POWDER DELIVERY PROCESS

Abstract

This study aimed to improve the product delivery process by focusing on a case study of a protein powder manufacturer in the pet food industry. Various steps in the process were examined, on a questionnaire, participatory observation, and a process flow chart. Pareto analysis was used to evaluate activity value and prioritize issues needing improvement. In addition, the causes of delays in the delivery process were assessed using the Why-Why analysis tool. The ECRS tool was applied to improve the product delivery process. The efficiency of the process was compared before and after this improvement using descriptive statistics. Based on the study result, batch and pooled sample quality analysis steps, along with associated waiting times, accounted for 99.68 percent of the total delivery process duration. The study achieved a 50.29 percent reduction in total delivery process time by improving the quality analysis process to facilitate better communication of results and organizing the sample pickup logistics. This also resulted in a 69.0 percent reduction in time spent on non-value-added (NVA) steps and a 34.61 percent reduction in time spent on non-value-added but necessary (NNVA) steps, along with a 51.02 percent decrease in the amount of minimum cash required to support operations, allowing the company to reallocate working capital toward value-added activities. These improvements enhanced customer satisfaction, as demonstrated by internal audit feedback and the repeat purchase behavior observed during the post-implementation period, indicating a positive shift in service perception.