Reema Al-Dalain
Abstract Lean manufacturing has proven effective across many industries, yet its application in food processing remains constrained by product perishability and process variability. This study develops a hybrid Lean–Simulation framework that integrates Gemba walks, check sheets, Pareto analysis, Fishbone diagrams, and Value Stream Mapping (VSM) with Monte Carlo simulation to capture both deterministic inefficiencies and stochastic variability. Results show an average processing time of 354.98 minutes, with the 95th percentile at 378.96 minutes, confirming that Thawing and Packing are the dominant bottlenecks. By incorporating probabilistic analysis, the framework extends beyond conventional Lean tools and provides managers with actionable insights to enhance stability, allocate resources strategically, and improve responsiveness in food processing operations.