The report presents a comprehensive study on implementing Digital Kaizen at a gum and candy manufacturing facility in Egypt, operated by Company X.
The initiative aimed to reduce waste, enhance packaging line efficiency, and enable real-time quality monitoring by integrating traditional lean tools—like Fishbone diagrams and Pareto analysis—with digital technologies such as Power BI dashboards and dynamic sampling systems. A key component of the project was the use of ExtendSim to simulate the packaging line under both old and expanded capacities, incorporating real-world parameters like machine rates, MTBF, MTTR, and rework levels.
Simulation results demonstrated significant improvements with the expanded configuration: output increased by 31.8%, cycle times dropped by 10.3% on Line 1 and 50.6% on Line 2, and the rework rate decreased by 4.7%. These findings validated the effectiveness of the capacity expansion and highlighted the value of simulation modeling in supporting data-driven decision-making and continuous improvement, aligning with the principles of Digital Kaizen.