Implementation of Lean manufacturing tools in an abattoir: A case study of a Botswana Private Beef Abattoir

Application of lean manufacturing tools in abattoirs promise great process improvements, despite limited sources and literature specific to abattoirs. Due to the inadequacy of research papers in application of lean manufacturing tools in abattoir; audits, process efficiency measurements, document analyzing, identification of value adding and non-value adding activities, site visits, plant tours, conducting trainings and awareness, motion study, work and method study, plant tour and observation were used. Data collection, recommendations and improvements were made on the basis of authors’ knowledge, observations, audits results, change management responses, feedbacks, process measurements, and abattoir staff advice. Lean manufacturing tools, practices and philosophies that succeeded in carrying out the research in abattoirs are takt, standardization, 5S and waste elimination, value stream mapping. These lean manufacturing tools improved business processes, work methods and productivity. This paper reports on the introduction of lean manufacturing tools in one of Botswana Private Beef Abattoir. The contribution highlights before and after lean implementation in terms cost saving improvements, work method improvements, workplace safety awareness, 21-23 % cycle time improvements, 20-22% process efficiency improvement and recommendation to waste management practices that the company can absorb