N. H. Osadiaye

This study investigated the impact of lean manufacturing practices on waste reduction in selected building block industries in Benin City, Edo State. The research was motivated by the persistent challenge of material wastage, process inefficiency, and delays that hinder productivity in the Nigerian building block sector. The main objective was to evaluate how the implementation of lean manufacturing principles such as 5S (Workshop Organization), Kaizen (Continuous Improvement), Total Productive Maintenance (TPM), and Just-In-Time (JIT) influences the level of waste reduction in block production operations. A descriptive survey research design was adopted, and data were collected using structured questionnaires administered to eighty (30) respondents drawn from production, maintenance, and quality control departments across selected block industries. The data obtained were analyzed using the Statistical Package for the Social Sciences (SPSS) and Microsoft Excel to ensure accuracy and robustness. Both descriptive statistics (percentages and mean scores) and inferential statistics (OneWay ANOVA, correlation, and regression analyses) were employed to test the hypotheses and establish relationships between variables. The results revealed that Total Productive Maintenance (TPM) has the strongest and most significant positive relationship accounting for 54% of material waste reduction, 5s showed a moderate positive but marginally significant relationship accounting about 35% of waste reduction, while Kaizen and JIT exhibited weak and insignificant correlations. The ANOVA result with a p-value of <0.001 further demonstrated that the difference in waste reduction across the lean tools and waste reduction are statistically significant. The study concludes that lean manufacturing practices have a moderate but significant impact on waste reduction with TPM emerging as the most influential tool. It recommends that building block production firms strengthens their lean adaptation strategies so as to achieve a higher level of productivity and sustainability.

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.