This thesis reports on the research undertaken to minimise wastes from overproduction that
are created to meet demanding due dates imposed by retailers in convenience food
manufacture. The principle objective of this research is to generate knowledge and generic
solutions to minimise the environmental impacts of such wastes through effective production
planning and improved processing and supply chain practices.
The research contribution is divided into three major parts. The first part reviews the most
relevant publications and legislation, and categorises the contemporary techniques in supply
chain management, operations management and production planning. The second part is
concerned with three novel concepts of (a) identifying, modelling and analysing the various
types of wastes in food industry (b) the systematic support for the improvement of production
and supply chain activities through generation of a Responsive Demand Management
framework, and (c) the realisation of a hybrid two stage planning approach for minimisation
of overproduction wastes. The final part demonstrates the application of these research
concepts through a case study for minimisation of overproduction waste within a ready-meal
The hybrid two stage planning approach has been shown to be an effective method by which
overproduction wastes can be addressed for products with production lead-times that exceed
order lead-times. The responsive demand management framework is a powerful method for
the identification and recording of production and supply chain inefficiencies that can be
utilised to establish a programme of improvements for further waste reduction.
Classification, modelling and analysis of food industry wastes by this research has provided
food manufacturing with significant tools to monitor and reduce environmental impacts. The
case study has effectively demonstrated the applicability of the research concepts in
significantly reducing overproduction waste.
In summary, this research has highlighted the environmental and economic impacts of waste
and has underpinned the paramount importance of establishing sustainable manufacturing
and supply chain procedures in convenience food sectors.
A Doctoral Thesis. Submitted in partial fulfillment of the requirements for the award of Doctor of Philosophy of Loughborough University.