LMRPID-397485
Page 32
21st August 2024
Integrating Industrial Automation and Lean Principles to Improve Productivity and Reduce Downtime in Advanced Manufacturing Environments: A Case Study in the Bangladeshi FMCG Industry
Author: RAKIBUL HASSAN | LGMID: 27199320190101971
Reviewed by:
Lilac Institute of Technology (LIT)
Paper preview
1. Abstract
2. Introduction
3. Literature Review
4. Methodology
5. Findings
6. Conclusion
7. References
Abstract
Bangladesh has emerged as one of the fastest-growing economies in South Asia over the past decade. With a densely populated landscape and rising per capita income, it offers a highly attractive market for investors. Given the concentration of consumers in a smaller area, supply chain efficiencies are increasingly becoming a competitive advantage. As a result, the country is witnessing rapid industrialization. However, despite this growth, the FMCG industry in Bangladesh significantly lags behind global benchmarks in productivity, efficiency, quality, and resource utilization. This gap stems from limited integration of automation technologies, continued reliance on manual labor, and a lack of widespread adoption of globally recognized manufacturing practices such as Lean methodologies. This thesis investigates how integrating industrial automation with lean manufacturing tools can address these gaps. A practical framework is proposed, combining automation technologies—such as PLCs, drives, industrial sensors, and monitoring systems—with Lean tools like 5S, Kaizen, ECRS, Muda-Mura-Muri, and Poka-Yoke. The framework was experimentally implemented in a six-line FMCG production facility. Comparative analysis was conducted between the experimental line and conventional lines, tracking metrics such as output per shift, defect rates, changeover time, and cost per tonnage. Despite initial setup challenges, the automated lean-integrated line delivered measurable improvements in productivity, quality, and waste reduction. The internal rate of return (IRR) also demonstrated strong financial justification for the initial investment. These findings highlight the transformative potential of merging automation with lean principles for the Bangladeshi FMCG sector. This thesis presents a practical roadmap for embracing technological advancement and lean thinking within the local manufacturing context. By doing so, industries in Bangladesh can build more sustainable, efficient, and competitive production systems—ultimately supporting national economic growth and industrial resilience.
References
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Keywords
Industrial Automation, Lean Manufacturing, Productivity, Downtime Reduction, FMCG Industry, Bangladesh
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