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This work presents the results of a case study aimed at revitalizing an agricultural equipment manufacturing consortium facing prolonged losses. The purpose of this paper is to enhance productivity and profitability by identifying and eliminating waste within the manufacturing processes. The study uses lean principles and tools to achieve this objective.

The study begins with the creation of a questionnaire, administered to the consortium to gather insights. The questionnaire responses serve as a foundation for pinpointing critical areas in need of immediate attention. To tackle the challenge of demand forecasting without customer data, a demand forecasting model is introduced. Value stream mapping (VSM) is used to identify and highlight process inefficiencies and waste. The findings are further analyzed using a Pareto chart to prioritize waste reduction efforts. Based on these insights, the study proposes alternative manufacturing methods and waste elimination strategies. A multiphase lean framework is developed as a step-by-step roadmap for implementing lean manufacturing.

The study identifies a broken process flow within the consortium’s manufacturing processes and highlights areas of waste through VSM. The Pareto chart analysis reveals the most significant waste areas requiring immediate intervention. Recommendations for process improvements and waste reduction strategies are provided to the consortium.

This study contributes to the field by applying lean principles and tools to address the unique challenges faced by an agricultural equipment manufacturing consortium. The integration of a demand forecasting model and the development of a multiphase lean framework offer innovative approaches to enhancing productivity and profitability in this context.