Productivity improvement using value stream mapping in a beef abattoir

Abstract

Beef abattoirs continue to face challenges of improving productivity, in order to remain successful in a highly competitive industry. As every input cost goes higher year on year, it is important to provide better products, processes and services at lower costs to the end user by improving process cycle time efficiency of the plant. The aim of this paper is to illustrate the implementation of value stream in a beef abattoir to improve productivity. This study started with conducting site visits, touring the plant, conducting interviews, direct observation and conducting time study for the existing current production process. Current process was mapped to identify problems and bottlenecks within the beef abattoir. Long manufacturing lead time, waiting or delays within the production and too much time spent on handling the carcass. In order to address these productivity inefficiencies in a beef abattoir; future state map, estimated calculated process improvements and suggestions were proposed on how value adding time can be improved. These proposed improvements and calculated process cycle time efficiency could lead to a better system for the organization under study. The contribution highlights 21-23% process cycle time improvements and efficiency.