Poultry feed industry is a pretty much active in a lot of countries and it is achieved market acceptance. The final products are supposed to meet certain specifications to fulfill the nutritional need for animals at different life periods. The final product for poultry is shipped in the form of pelleted feed for the convenience of consumption. This paper focuses on improving production rates while maintaining quality specifications of the final products in an Egyptian poultry feed factory. The improvement approach is conducted by observing the main operating parameters of productivity; statistical analysis is conducted to observe the effect of those parameters on the production rate and the quality of the product. Comparison between parameters levels is done through analysis of variance to determine the significance of the tested parameters. The optimization of parameters was applied with Minitab and designed expert software to determine the best operating conditions. The obtained results showed that the downtime decreases by 16% monthly and the productivity increased by 35% and the pellet durability index increased by 0.8% after applying these parameters with total saving 2,160,000 LE.

The global economic crisis forces many industrial companies to be more concerned in reducing unnecessary cost, and eliminating all possible wastes inside the production lines. So that, most of companies focused on adopting the lean production tools [1]. The core idea of lean manufacturing is actually quite simple; relentlessly work on eliminating wastes from the manufacturing process. These wastes have a direct impact on costs, and profit [2]. Real-life problems can be modelled as linear programs. Linear programming is a problem-solving approach developed for situations involving maximizing or minimizing a linear function subject to linear constraints that, limit the degree to which the objective can be pursued. The objectives of this paper are to develop methods to reduce the waste in the different manufacturing processes in a technical support unit of Airplanes. This paper focuses on developing a linear programming approach in order to reduce the waste of material used in the production line. Single Minute Exchange of Die methodology (SMED) was implemented in order to reduce the changeover time. The achieved results showed that the linear programming is an effective and cheapest tool in optimizing the waste in the production lines. By using linear programming, the organization can reduce the wasted materials from 15.1% to 6.6%, with annual costs saving 288,480 Egyptian pounds (EGP). The achieved results from implementing a simple lean production tool such as, SMED helps the organization to reduce the changeover time by 44%, with annual costs saving 29,440 EGP.

Many companies are looking at lean manufacturing for helping them to remain competitive; Lean manufacturing is however more than just a set of tools and techniques as it also requires a change in the organizational culture of the company involved to be a lean culture. The relationship between an organization's culture and its ability to implement lean six sigma technique is a long-term effort. As a first step, the purpose of this paper is to offer the results of a survey conducted to measure the lean cultures criteria in the manufacturing company which is conducive for successful implementation of lean six sigma methodologies. The method used for this paper study was the questionnaire method using a lean culture assessment questionnaire that has been designed by the researcher that was aligned to the important principles based on Toyota Way model. This study indicates that the existing organizational culture of radiator Production Company is relatively conducive to the implementation of lean principles within the company. KEY WORDSLean manufacturing, organizational culture, lean culture assessment, questionnaire.

Lean manufacturing philosophy is continually strive to eliminate the nun-value added activities, minimize the delivery cycle time and improve the quality of products. Most manufacturing companies adopt lean in order to meet customer expectations and become more competitive in the market. Implementation of Lean enterprise is an efficient and effective way to reduce the cost of the enterprise without incurring high capital expenditures. SMED is a popular lean tool used for dramatically reducing the set-up time for the machine, which is a set of techniques enabling for the replacement of tooling or set a production line in less time than 10 minutes. This paper focuses on implementing SMED methodology in a mass production company for food industries in order to reduce changeover time. The objectives of this paper are decreasing the setup times of the production line to enable the production flexibility and increase the maneuverability between different products according to customer needs. This paper monitoring carefully all production processes to identify all wasted time between processes and find ways to eliminate or decrease it. The achieved results indicate that implementation of SMED in the company has a significant impact on decreasing the setup times and increasing the total productivity and the net profit. The changeover time reduced by 25%, and the OEE increased from 48% to 70%, also, the sales opportunities increased by 465,600 EGP per year. KEY WORDSLean production, Single Minute Exchange of Die (SMED), OEE, improve the productivity.---

The poultry feed industry is pretty much active in a lot of countries and it is achieved market acceptance. The final products are supposed to meet certain specifications to fulfill the nutritional need of animals at different life periods. The final product for poultry is shipped in the form of pelleted feed for the convenience of consumption. One of the major challenges of poultry feed production is the principal complement of equipment necessary for the local production. Imported poultry pellets are quite expensive and unaffordable for many poultry feed industries. Hence, the need to be able to produce poultry feed at lower cost yet achieve the objective of quantity and quality expected of pelleted feeds is critical to the viability of the enterprise. The study aims to investigate the effects of some operating parameters (pressure and temperature of the compounded feed) and die hole size on the pelleting efficiency, throughput capacity, and to optimize the conditions. The improvement approach is conducted by observing the main operating parameters of productivity; statistical analysis is conducted to observe the effect of those parameters on the production rate and the quality of the product. Comparison between parameter levels is done through analysis of variance to determine the significance of the tested parameters. The optimization of parameters was applied with Minitab and designed expert software to determine the best operating conditions. The obtained results showed that the downtime decreased by 77% monthly and productivity increased by 32.5% per hour and the pellet durability index increased by 1.23%. The total sales increased by 6,750,600 LE/Month.