OKHUELEGBE ANTHONY ODION

The food and beverage manufacturing sector in Edo State is an important part of Nigeria’s industrial economy but faces major inefficiencies, including spoilage, defects, and overproduction. Lean manufacturing, derived from the Toyota Production System, offers a structured approach to eliminating waste and improving performance. Tools such as 5S, Kaizen, Just-in-Time (JIT), and Total Productive Maintenance (TPM) have proven effective in boosting productivity, although lean adoption in developing countries remains limited by infrastructural weaknesses, supply chain issues, and resistance to change. This study evaluates the contribution of lean practices to waste reduction and operational efficiency in selected food and beverage firms in Edo State. A mixed-methods design was adopted, using descriptive and analytical approaches. Data were obtained from 30 purposively selected firms through questionnaires, interviews, and direct observations. Descriptive statistics were used to categorize waste types, while regression and correlation analyses assessed the relationship between lean practices and waste reduction. Thematic analysis further examined barriers to implementation, and SPSS with Microsoft Excel ensured accurate data analysis. Findings indicated that spoilage was the most widespread form of waste, followed by defects and overproduction. Lean practices, especially 5S and JIT, significantly improved waste reduction, accounting for 67% of the variation in performance. However, unstable electricity supply, insufficient employee training, and unreliable suppliers weakened overall lean adoption. The study recommends a gradual implementation of lean, starting with easier-to-apply tools such as 5S and Kaizen, along with capacity-building programs and strengthened supply chain collaboration. Policy support for infrastructure and industry-focused training is essential to improve lean outcomes and support long-term sustainability.