LEAN MANUFACTURING


a strong lean foundation, digital tools risk becoming isolated systems that generate data but fail to drive meaningful improvement. Dashboards without problem-solving routines, or sensors without standardised processes, will


rarely translate into sustained


performance gains. Lean provides the discipline needed


to allow organisations to accelerate the benefits of IIoT technology – offering clear processes, structured problem solving, and a culture focused on value creation, while IIoT provides real-time visibility, predictive capability, and faster decision-making. The most successful confectionery


organisations are not choosing between the two. They are integrating them and this convergence represents a shift from isolated improvement initiatives to fully connected, data-driven operations grounded in


is evolving. “In our view, IIoT and smarter factories do not replace lean principles; they strengthen them. Lean has always been about reducing waste, improving flow, increasing transparency and enabling continuous improvement. Digital technologies now make these principles far more actionable and scalable,” she said. For confectionery manufacturers,


this could mean moving from reactive optimisation to proactive, data-driven improvement. IIoT-enabled equipment can provide real-time insights into machine performance, process stability, recipe consistency, changeover times and material usage. This allows teams to identify inefficiencies earlier, reduce unplanned downtime, improve overall equipment effectiveness, and make better- informed decisions across the entire line. However, Sandra also pointed out that


lean thinking. Kaizen


Institute pointed out that with this model, continuous improvement is no longer periodic; it becomes embedded in daily operations, supported by live data and cross-functional collaboration.


A lean evolution Sandra Link, Product Manager at Syntegon, also argued that


lean manufacturing


remains highly relevant in confectionery production – but she acknowledges that it


digitalisation alone is not lean. She said: “Simply collecting more data does not automatically create more value. The real benefit comes when manufacturers combine digital tools with a lean mindset – clear processes, standardisation, operator empowerment, and a strong focus on eliminating non-value-adding activities. In that sense, smart factories should be seen as the next stage of lean manufacturing rather than its replacement.” This becomes particularly evident in


confectionery processing. In gummy, jelly and other sugar confectionery applications, manufacturers are under pressure to manage increasing product and portfolio complexity while ensuring consistent quality and minimising waste and according to Sandra, this is where Syntegon’s Makat portfolio has a key role to play. “Advanced cooking, mixing, depositing and product finishing systems enable highly stable processes, precise dosing and repeatable product quality – even for complex recipes,” she said. By combining intelligent process


technology with data-driven insights, confectionery manufacturers are better able to detect and reduce variability at an early stage. This not only improves product quality, but also reduces material losses, waste and rework – all central objectives of lean manufacturing. “At the same time, automated processes and optimised line concepts enable shorter changeover times and greater flexibility when switching between products,” continued Sandra. In short, she argued that lean


continues to define the direction of travel in confectionery manufacturing. while modern process and IIoT technologies provide the tools to achieve these goals faster, more precisely and more sustainably.


MAY 2026 • KENNEDY’S CONFECTION • 37


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