Application of Lean Manufacturing Techniques to Low Density Polyethylene Recycling Processes: A Value Stream Mapping Approach

Purpose: The aim of this study is reducing waste and improve process efficiency in the recycling of low-density polyethylene (LDPE) by applying lean manufacturing principles. Method: Main stages in the production process Preliminary Preparation Line, Granule Extrusion Line, Film Extrusion Line, and Film Cutting Machine were examined. The current state was mapped using the Value Stream Mapping (VSM) technique. Identified wastes were addressed with lean tools, and a future state map was developed accordingly. Findings: The analysis showed types of waste including waiting periods, unnecessary transportation, and overproduction. Improvement efforts led to reduced cycle time, fewer bottlenecks, and more efficient use of resources. The comparison between current and future states demonstrated a notable increase in overall performance and productivity. Originality: This study offers a unique and sector-specific approach by implementing the VSM technique, which is rarely used in the plastic recycling industry. Its originality lies in adapting lean principles to recycling. Moreover, practical improvement suggestions based on actual field data provide guidance for similar businesses aiming to enhance operational effectiveness.