Analysis of Quality Improvement Using Kaizen-PDCA for Resource Efficiency and Green Productivity: Case Study in Beverage Industry

Abdul Wahid; M. Imron Mas’ud; ayik Pusakaningwati

doi:10.35891/yn44wp12

Authors

Abdul Wahid
M. Imron Mas’ud
ayik Pusakaningwati

DOI:

https://doi.org/10.35891/yn44wp12

Keywords:

Beverage Industry, Green Productivity, Kaizen, PDCA Cycle

Abstract

The beverage industry requires strict process control to ensure resource efficiency and product quality. This research aims to analyze the implementation of the Kaizen method and PDCA (Plan-Do-Check-Act) cycle in reducing raw material losses at PT XYZ. Using a descriptive qualitative approach, data were collected through direct observation, interviews, and documentation on the yogurt drink production line. Initial observations identified high raw material losses averaging 2.1%, exceeding the company’s benchmark. Improvement actions included shortening the filling line by 50%, installing sight glasses for real-time monitoring, and standardizing procedures through One Point Lessons (OPL). The results showed a significant reduction in raw material losses to 1.0%, resulting in a monthly financial saving of approximately IDR 10,192,000. Additionally, filling process efficiency increased from 96% to 98.5%. This study concludes that the integration of Kaizen and PDCA effectively supports green productivity by minimizing production waste and enhancing operational sustainability in the beverage processing industry

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