OPTIMIZING LEAN MANUFACTURING PRACTICES FOR WASTE REDUCTION AND PRODUCTIVITY ENHANCEMENT IN INDUSTRIAL SYSTEMS

Abstract

This study investigates the optimization of Lean Manufacturing (LM) practices for waste reduction and productivity enhancement in industrial systems. The research combines qualitative and quantitative methods to assess the impact of Lean practices, technological integration, and employee involvement on operational performance. Data were collected from interviews with plant managers and Lean practitioners, surveys with employees, and secondary data from manufacturing reports. The findings reveal a 36.67% reduction in waste and a 30% improvement in productivity following the implementation of Lean practices. Technological integration, particularly through the use of Artificial Intelligence (AI) and the Internet of Things (IoT), contributed to a 25% increase in machine efficiency, highlighting the importance of modern technologies in optimizing Lean systems. The research demonstrated that when employees were deeply involved in decision-making processes their location experienced both better productivity levels and reduced waste output through a 45% productivity increase and 40% waste reduction. Operational improvements of significance occur when organizations use Lean practices alongside technological innovation and active workplace engagement. The findings demonstrate that contemporary manufacturers need complete optimization models for their facilities while offering actionable tips to optimize efficiency together with waste reduction performance. Future investigations must concentrate on verifying the permanent implementation of these methods along with their applicability across multiple industrial applications.