| Abstract: |
Lean manufacturing, originating from the Toyota Production System (TPS), is globally recognised as a strategic methodology for improving productivity and eliminating operational waste. This study investigates the impact of core lean tools 5S, Kaizen, Value Stream Mapping (VSM), Just-In-Time (JIT), and Total Productive Maintenance (TPM) on operational productivity across manufacturing sectors. The primary objective is to assess how systematically implemented lean techniques influence production lead time, defect rates, labour productivity, and overall equipment effectiveness (OEE). A descriptive-analytical research design was employed, drawing on secondary data from peer-reviewed literature, verified global industry reports, and manufacturing case studies covering the period 2020–2025. The study hypothesises that structured deployment of lean techniques significantly improves productivity indicators in operations management. Results from tabulated data confirm reductions in production lead time by up to 70–90%, defect rate reductions of up to 80%, and average labour productivity gains of 21–35% post-implementation. These findings align with benchmarks from McKinsey & Company, the Lean Enterprise Institute, and the U.S. Bureau of Labor Statistics. The study concludes that lean manufacturing remains a measurable, evidence-backed framework for operational excellence. |
