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Purpose This study aims to enhance productivity in the production of 122 mm rocket warheads at the Heavy Ammunition Factory (HAF) by implementing lean manufacturing concepts to optimize resource utilization. Design/methodology/approach A case study approach was adopted, using quantitative methods to collect data on the production process. Time and motion studies were conducted using a stopwatch to assess cycle time for 33 operations, enabling the calculation of standard allowed minutes (SAM), takt time and efficiency. The current state value stream map (CSVSM) was created to identify improvement areas, leading to the implementation of 25 kaizen initiatives focusing on manufacturing, quality, cost and delivery, resulting in a future state value stream map (FSVSM). Findings The application of lean manufacturing tools significantly improved overall productivity, enhancing customer satisfaction regarding quality, cost and delivery. Key outcomes included reduced operations, lower manpower costs, decreased cycle time and takt time and increased daily productivity, confirming the effectiveness of lean practices. Research limitations/implications A key limitation of value stream mapping (VSM) is its focus on a single manufacturing line for the 122 mm rocket warhead, which reduces applicability and highlights its static nature. This study used only three lean tools, time and motion studies, kaizen and VSM without incorporating cost flow, focusing solely on information, material and process flows. Additionally, the case study was limited to the HAF. Practical implications Addressing productivity in ammunition manufacturing is crucial, achievable through lean tools that identify and eliminate waste. The findings can guide other industries in adopting lean practices, aiding managers in recognizing improvement opportunities. Social implications Enhanced productivity in ammunition manufacturing directly contributes to the production of higher-quality defense products, reinforcing national security and operational readiness. In a developing country context, increased efficiency translates into better resource allocation and potential cost savings for government and military budgets-critical benefits for public sector sustainability. From a labor perspective, process optimization can stabilize employment levels at facilities like HAF by maintaining production demands without resorting to downsizing. On a broader scale, successful implementation of lean techniques in defense manufacturing supports national self-sufficiency and industrial competitiveness. Local economies benefit through job creation, capacity building and infrastructure investments tied to a thriving manufacturing ecosystem. Originality/value This case study presents a pioneering application of SAM for the manufacturing of 122 mm rocket warheads within a developing country context-a domain notably underrepresented in existing literature. The case study distinguishes itself by combining traditional lean manufacturing techniques with practical defense production insights from the HAF facility.
Fulasa et al. (Fri,) studied this question.