Efficient resource utilization and waste reduction are vital for enhancing manufacturing profitability. This study examines production processes within the pipe manufacturing sector, focusing on identifying and reducing non-value-added activities, commonly called "waste," which contribute to elevated operational costs. Waste manifests in visible forms, such as idle time and excess material usage, and hidden forms, like redundant movements and inefficient setups. By applying lean methodologies Value Stream Mapping (VSM), 5S, Single-Minute Exchange of Dies (SMED), and Kaizen this study aims to address these inefficiencies, thereby improving productivity and cost-effectiveness. The results indicate significant reductions in Production Lead Time (PLT) from 30 to 10 days and Processing Time (PT) from 145 to 123 minutes. Lean tools, previously used minimally, were expanded to include 5S, SMED, Stage Inspection (SI), and Just-In-Time (JIT), leading to improved efficiency in uncoiling, forming, and inspection stages. Additionally, the reorganization of workflows through 5S reduced unnecessary motion and delays. This study demonstrates the impact of lean tools in minimizing waste and provides a framework for pipe manufacturers seeking to optimize processes, control costs, and strengthen their competitive positioning.

Keywords: Lean Manufacturing, Waste Reduction, Productivity Optimization, Pipe Manufacturing, Value Stream Mapping (VSM).