Coexistence of the BRC Standard for Packaging and the Lean Manufacturing methodology

Urban, Wiesław; Ratter, Emil; Wangwacharakul, Promporn; Poksińska, Bonnie

doi:10.2478/emj-2018-0016

Cited by 2 publications

(13 citation statements)

References 19 publications

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“…From the literature review, it is known that the implementation of the BRC standard with a Lean methodology is not very common. However, the integration of both concepts could be a viable idea (Urban et al, 2018). Especially because they share common goals: the creation of value in a product and providing good quality products (Urban et al, 2018).…”

Section: Brc Certification and Lean Tools Integrationmentioning

confidence: 99%

“…Interestingly, they share core requirements, and can work as one. The use of these systems has been gaining gradual interest in companies (Urban et al, 2018). This is the case of an Ecuadorian company that manufactures flexible packaging for food.…”

Section: Introductionmentioning

confidence: 99%

“…However, case studies regarding certifiable programs are scarce. Kawecka (2018) and Urban et al (2018) conducted studies on certifiable programs. Moreover, as a certified food safety management system (FSMS), BRC has been widely analyzed in the food industry (Chaoniruthisai et al, 2018;Piira et al, 2021), and specifically in the packaging industry (Karam et al, 2021), where the appropriate handling and storage practices to reduce the risk of contamination are being studied.…”

Section: Introductionmentioning

confidence: 99%

“…In spite of that, articles that present the feasibility of merging Lean and BRC systems into one, specifically in the flexible packaging industry are scarce. Urban et al (2018) review the potential impact of the coexistence of both the Lean methodology and the BRC standard. This study demonstrates that their merging is possible since they share the same objectives, which is to ensure the quality of the products in order to generate value for customers.…”

Section: Introductionmentioning

confidence: 99%

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Characterizing the integration of BRC food safety certification and lean tools: the case of an Ecuadorian packaging company

Bravo-Paliz

Avilés-Sacoto

2022

TQM

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PurposeWorldwide, companies are interested in improving processes and reaching high levels of quality through the adoption of various systems. For example, they implement quality management methodologies, such as Lean, with the aim of reducing waste and cost. In the food sector, however, companies also adopt food safety management systems, such as BRC (British Retail Consortium), destined to comply with the standards of hygiene, food safety and quality systems. Interestingly, both Lean and BRC seek to boost quality. Thus, both should be able to work as a single system and cooperate to add value to a company without duplicating efforts. By solving the problems in the bag sealing process of an Ecuadorian company through the implementation of Lean tools incorporated in the steps of the DMAIC methodology (define-measure-analyze-improve-control), and then framing a cooperation matrix of Lean tools and BRC clauses, this paper seeks to demonstrate their feasible cooperation.Design/methodology/approachOne of the most well-known methodologies for process improvement is the DMAIC methodology. Through the sequence of the DMAIC steps, the main problem of an Ecuadorian company that produces flexible packaging for food was identified. With the voice of the customer (VOC) from historical customer surveys of the company, the common issues were found. Similarly, historical data of non-conformities required by ISO-9001: 2015 provided insightful information for this phase. In order to measure the current quantitative state of the processes, a VSM (value stream map) was jointly employed with an operator balance chart. Data was collected during the whole operational month. Having this quantitative data, and with the ideas generated from the Kaizen events, improvement initiatives were analyzed and proposed. The proposed solutions involve production and maintenance teams. After some tests, it was verified that all these improvements had had a positive impact on the company. Finally, it was analyzed that Lean tools can collaborate and also be used as proof for BRC requirements. Thus, a correlation matrix between them was built, which demonstrates cooperation between both systems.FindingsThe results of this study indicate that Lean can cooperate in the pursuit of the BRC Standard for food packaging companies. This is shown through the case study of the Ecuadorian company, which implemented Lean tools and reduced its costs by shortening lost time and reducing set up time in the machines employed to cut and seal bags. Additionally, overall equipment effectiveness (OEE) from machines 1 and 2 rose their values considerably. Since BRC is a certifiable standard, it contains clauses that must be achieved in order to get the certification. By using Lean tools, it was possible to comply with some of the clauses of the BRC standard. A matrix was built so that it could be identified that Lean tools can work together with BRC, and thus, reduce costs and waste, while simultaneously complying with the safety and quality standards that the standard guarantees.Research limitations/implicationsThis research had two limitations. The first limitation is related to time. The data was collected in a month due to the project's deadline. For further research, it is recommended to increase this period of time to at least three months of production. The second limitation is related to the processes studied, which are associated with the time period. This study encompasses two major processes, which present major problems. For further investigations, longer periods of time can allow to include more processes from the company.Practical implicationsThe implications of this project rely on the fact that the company achieved a better level of efficiency. The application of Lean tools reduces waste in the company. Basically, the waste was associated with lost time in machines 1 and 2 from the cutting and sealing processes, which was mainly produced by mechanical malfunction and inefficient maintenance. These problems had a direct relationship with the bad quality of the bags since the machines operate almost fully automatically. Additionally, mechanical problems caused by inefficient maintenance have a direct impact on quality aspects of the bag, like correct dimensions or a proper seal. Moreover, these problems generate a loss of time since the operator must stop the machine during production time in order to fix it. Machines 1 and 2 reduced their lost time drastically. Furthermore, by using Lean tools alongside the BRC methodology, the company can now reduce the resources that are destined for Lean projects and the BRC certification. Specifically, as a result, Lean tools and their documents can serve as proof of compliance with certain BRC clauses.Social implicationsThese improvements impact the company's profits, and therefore the workers. Since there is a significant reduction in the company's costs, and also an increment in the company's production, the company will probably require hiring new employees. In this way, more job opportunities will be generated.Originality/valueThe originality of this work relies on the nature of the research and the type of production facility. Previous studies have examined Lean tool applications in many settings. There are a few studies regarding the adoption of BRC standards. However, and definitely, the merge between Lean tools and a food safety management system is novel, since there are few to almost no articles that have been published using such a merge. The positive outcomes that were obtained not only prove that both methodologies are compatible, but they can also encourage further research on the applicability and functionality of merging two methodologies similar to the ones used during this research. Regarding the production facility, very few articles have been published about flexible packaging companies, and this article will help further research in this field.

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Section: Brc Certification and Lean Tools Integrationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Characterizing the integration of BRC food safety certification and lean tools: the case of an Ecuadorian packaging company

Bravo-Paliz

Avilés-Sacoto

2022

TQM

View full text Add to dashboard Cite

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“…In addition to the requirement of the standard, it should be remembered that this is a legal requirement. Also, the paper [15] turns attention to the list of packaging suppliers and the list of requirements for packaging must be available. Approval parameters and test rates must be precisely defined, implemented and reviewed.…”

Section: Literature Review and Problem Statementmentioning

confidence: 99%

Development of recommendations on the hierarchy of activities regarding the implementation of the BRC standard in relation to the safety of packaging using the AHP method

Kawecka

Cholewa-Wójcik

Sikora

2021

EEJET

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The British Retail Consortium Global Standard for Food Safety enjoys great popularity among food industry companies, the number of companies with the certified standard is rising every year. The packaging used for food packaging has a very large impact on the safety and quality of the packaged food. The purpose of the study was to indicate the requirements of the standard in relation to packaging, which should be implemented firstly by enterprises of the food industry. In the research part, the AHP analysis was conducted on the basis of the experts' recommendations. Decision matrixes for every criterion: hazard analysis concerning packaging, purchase procedure, packaging acceptance procedure were developed. A decision matrix for the main criterion as a result of criteria decision matrix was developed, global decision hierarchy was also developed. Research clearly showed that the most important activity (among the proposed) is hazard analysis, with a 0.517 weighted sum value. In many of the detailed requirements of the standard, hazard analysis and risk assessment (0.333 weighted sum value) are the basis for many activities, including establishing a purchasing procedure (0.163 weighted sum value), accepting packaging (0.297 weighted sum value), or many others. The relevance of this study is the identification of the hierarchy of importance of activities performed within the framework of ensuring the quality and safety of food packaging. A reasonable approach is presented. The AHP method allows indicating the sequence of activities during the implementation of the BRC standard, as evidenced by pilot studies carried out on the basis of procedures related to the safety of packaging. The standard sets up requirements for packaging in the form of packaging management procedure, in which it should be stated how the site operates with packaging. Moreover, there are requirements concerning hazard analysis in relation to packaging

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Coexistence of the BRC Standard for Packaging and the Lean Manufacturing methodology

Cited by 2 publications

References 19 publications

Characterizing the integration of BRC food safety certification and lean tools: the case of an Ecuadorian packaging company

Characterizing the integration of BRC food safety certification and lean tools: the case of an Ecuadorian packaging company

Development of recommendations on the hierarchy of activities regarding the implementation of the BRC standard in relation to the safety of packaging using the AHP method

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