Lean in Animal Feeds

Improved production throughput without additional manpower or machines; enhanced floor space utilization and reduced non-value-added activities by

• Redesigning material flow from raw material store to batching and packing to eliminate unnecessary movements and waiting.
• Applying layout re-engineering and line balancing to minimize transport distances, congestion, and manual handling.
• Implementation of flow manufacturing concepts—sequenced batching, calibrated scales, and synchronized grinding-pelleting operations—to achieve smooth process flow.
• Implementation of Daily Work Management and standardized work methods to sustain consistency across shifts.

Stable equipment availability, reduced breakdowns, and longer component life by

• Conducting  machine-wise breakdown analysis to identify high-frequency failure points (e.g., grinders, elevators, mixers).
• Using Root Cause Analysis (Fishbone, Why-Why) to identify technical and human-related causes of downtime—like worn-out beaters, imbalance, poor fastening, or weak casing.
• Implementation of Preventive & Predictive Maintenance (TPM) and standardized lubrication and inspection checklists for critical equipment.
• Building skill among operators to identify early warning signs such as vibration, noise, or abnormal load.

Reduced batching time, smoother scheduling, and improved shift productivity by:

• Analyze batching cycle time using time and motion studies to identify bottlenecks and delays.
• Streamline batching sequence, eliminate waiting for material weighing, and introduce visual scheduling boards.
• Standardize weighing and trolley loading practices with calibrated scales and uniform material flow paths.
• Use 5S and visual workplace systems to ensure materials and tools are accessible at point of use.

Improved pellet quality, reduced fines, fewer customer complaints, and increased usable yield by:

• Using advanced Lean Six sigma tools such as Design of Experiments (DOE) to improve Pellet Durability Index (PDI) and reduce rework due to fines.
• Optimization of conditioning temperature, feed rate, and steam pressure to improve pellet binding strength.
• Establishing preventive maintenance and inspection of roller, die, knife, and paddles for uniform conditioning and cutting.
• Implementation of TQM tools and process capability tracking to stabilize PDI across batches.

Improved overall yield percentage, reduction in raw material variance, and optimized cost per ton of feed by

• Mapping losses across batching, pelleting, and packing stages using data-based variance analysis (input vs. output).
• Identifying major contributors like dust loss, incomplete bag emptying, sludge, and moisture loss using Pareto and cause–effect analysis.
• Standardization of bag handling, weighing accuracy, and trolley usage to reduce micro losses.
• Implementation of Pull/Kanban systems between process stages to prevent overproduction and spillage.
• Standard weighing and calibration routines and maintain moisture balance during conditioning and cooling.

Improved workplace discipline, safety, and faster identification of abnormalities by

• 5S / 5K audits across all process areas—grinding, batching, pelleting, and packing.
• Elimination of obstructions, improve accessibility of tools and materials, and maintain equipment cleanliness and safety.
• Create visual standards, equipment tags, and condition boards to make abnormalities visible at a glance