Applying System Dynamics to Evaluate Lean Manufacturing Interventions in a Traditional Bakery: A Case-based Conceptual Approach
DOI:
https://doi.org/10.24002/ijieem.v8i1.11805Keywords:
5S, causal loop diagram, lean manufacturing, SME bakery, system dynamics, workflow efficiencyAbstract
Small and medium-sized enterprises (SMEs) in the traditional food sector often face operational inefficiencies caused
by disorganized workspaces, inefficient layouts, and limited adoption of structured improvement practices. These
challenges are particularly evident in small bakeries where manual production processes and spatial constraints disrupt
workflow continuity. This study aims to analyze the relationships between operational inefficiencies and Lean
Manufacturing interventions using a System Dynamics approach. A qualitative case study was conducted at Toko Roti
Gelora, a traditional bakery in Jakarta, Indonesia. Data were collected through direct observation, informal interviews,
and document analysis over a ten-week field study. Lean diagnostic tools, including Value Stream Mapping and
Fishbone Diagram analysis, were employed to identify sources of operational waste. The findings were synthesized into
a Causal Loop Diagram (CLD) to represent feedback structures influencing production efficiency. The results identify
four key feedback loops shaping the bakery’s operations: two reinforcing loops representing the escalation of
inefficiencies and the development of Lean culture, and two balancing loops representing system stabilization through
5S implementation and layout improvements. These interactions suggest how Lean interventions may contribute to
reducing search time, motion waste, waiting time, and excess inventory while supporting the development of workplace
discipline over time. The study contributes by integrating Lean Manufacturing and System Dynamics to propose a
systemic framework for analyzing operational efficiency in SME production systems.
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Copyright (c) 2026 Fredy Sumasto, Najla Aulia, Arif Setiadi, Fahriza Putra Zaman, Muhammad Raihan Adil, Febriza Imansuri, Indra Rizki Pratama, Dianasanti Salati, B. Handoko Purwojatmiko
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