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Productivity Improvement Applying “Theory of Constraints” Approach – An in-depth case Study in An Agro-Processing Organization in Bangladesh

Corresponding Author : M. H. Kibria (kibria-ipe@sust.edu)

Authors : M.H. Kibria (kibria-ipe@sust.edu), M. A. Islam (arif-ipe@sust.edu), J. Hasan (j.hasan-ipe@sust.edu), C. A. A. Rashed (rashed-ipe@sust.edu)

Keywords : Productivity, Efficiency, Line balancing, Theory of Constrains, Drum-buffer-rope

Abstract :

The Agro and Food processing industry is a rapidly growing sector in Bangladesh. It employs a significant portion of the labor force in the country. This sector exports many items, including processed food products such as frozen fish, shrimp, food in dry form, processed meat, ready-to-cook food like paratha, dal puri, etc., and earns considerable

foreign currency. It has indeed more potential to earn as global demand is upraising. To cope-up with competitive edges, the industry must increase productivity by ensuring quality. To improve the line efficiency and productivity, the line should be well balanced. Many tools and techniques are generally applied to increase productivity. Applying the Theory of Constraints (TOC) approaches in this sector is rare. A food processing factory was encountering problems with lower productivity despite applying some lean tools and engaging better technologies. This action research was conducted to solve the real-life problem of the factory. A major production line was taken for the scientific study and was attempted to identify the underlying bottlenecks and finally to make the line well balanced by applying different steps of the TOC approach. Data have been collected on the spot engaging various timeframes for the same purposes in-depth. The drum-buffer-rope concept, along with other lean tools, was applied to find out the optimal solution. The study has discovered the following benefits: productivity improvement up to 2.18 times of the existing productivity, increase the line efficiency by 85% and reduce the cost per unit production by 13%. It can be concluded that the TOC approach with other lean tools will be highly beneficial, and less time consume.

Published on October 23rd, 2024 in Volume 4 Issue 2, Mechanical, Manufacturing & Industrial Engineering