Reducing the percentage of broken drops using the lean six sigma methodology
Reducing the percentage of broken drops using the lean six sigma methodology
Índice
Purpose – This paper aims to demonstrate the empirical study regarding the implementation of a Lean Six Sigma project through the DMAIC method to reduce the percentage of broken drops in the manufacturing process of a food factory.
Design/methodology/approach – The research was carried out through a single and longitudinal case study, where the interviews followed the sequence of steps and practices observed in the theoretical framework.
Findings – The analysis performed in this project indicated that the presence of bubbles in the dough had influenced the percentage of broken drops. The main root causes of the problem were identified as conveyor belt, nozzles, and cold chamber. The project allowed an increase of 4.79% in the final process yield index and the sigma level evolved from 2.87σ to 3.25σ.
Research limitations/implications – The research results are limited to a single case study, and it is not intended to generalize the results to other types of industry.
Practical implications – This paper can be used as a reference guide for researchers and practitioners to implement operational excellence projects in their organizations, following the steps presented in this study.
Originality/value – This paper is a real case study on Lean Six Sigma practices in a food factory. This sector still lacks empirical studies regarding the implementation of operational excellence strategies.
See paper
Andersson, R., Hilletofth, P., Manfredsson, P., and Hilmola, O.P. (2014), “Lean Six Sigma strategy in telecom manufacturing”, Industrial Management & Data Systems. Vol. 114, No. 6, pp. 904-921.
Bass, I., and Lawton, B. (2009). “Lean six sigma using SigmaXL and Minitab”. McGraw Hill Professional.
Berenson, M., Levine, D. and Krehbiel, T. (2002), “Basic business statistics: Concepts and applications”, New Jersey: Prentice Hall.
Black, K., and Revere, L. (2006), “Six Sigma arises from the ashes of TQM with a twist”, International Journal of Health Care Quality Assurance, Vol. 19, No. 3, pp. 259-266.
Byrne, G., Lubowe, D., and Blitz, A. (2007), “Using a Lean Six Sigma approach to drive innovation”, Strategy & Leadership, Vol. 35 No. 2, pp. 5-10.
Chakraborti, S., Human, S.W., and Graham, M.A. (2009). “Phase I statistical process control charts: an overview and some results”. Quality Engineering, Vol. 21, No. 1, pp. 52-62.
Corbett, L.M. (2011), “Lean Six Sigma: the contribution to business excellence”, International Journal of Lean Six Sigma, Vol. 2 No. 2, pp. 118-131.
Creswell, J.W. (2007), “Projeto de pesquisa: métodos qualitativo, quantitativo e misto”, 2ª ed. Porto Alegre: Artmed.
De Koning, H., and De Mast, J. (2006), “A rational reconstruction of Six‐Sigma’s breakthrough cookbook”, International Journal of Quality & Reliability Management. Vol. 23, No. 7, pp. 766-787.
De Mori, C. (2011), “Capacidade tecnológica em sistemas agroindustriais: proposição de índice e aplicação a empresas dos segmentos de trigo e leite”, (Doctoral thesis). Federal University of São Carlos. Available at: https://repositorio.ufscar.br/handle/ufscar/3391 (accessed March 9 2020).
Desai, D. A., Kotadiya, P., Makwana, N., and Patel, S. (2015), “Curbing variations in packaging process through Six Sigma way in a large-scale food-processing industry”, Journal of Industrial Engineering International, Vol. 11, No. 1, pp. 119-129.
Dora, M., and Gellynck, X. (2015), “Lean Six Sigma implementation in a food processing SME: a case study”, Quality and Reliability Engineering International, Vol. 31, No. 7, pp. 1151-1159.
Dudbridge, M. (2011), “Handbook of lean manufacturing in the food industry”. John Wiley & Sons.
Evans, J.R., and Lindsay, W.M. (2014), “An introduction to Six Sigma and process improvement”, Stamford: Cengage Learning.
George, M.L. (2002), “Lean Six Sigma: Combining Six Sigma Quality with Lean Speed”, New York: McGraw-Hill.
Goodman, E. (2012), “Information analysis: a lean and Six Sigma case study”, Business Information Review, Vol. 29 No. 2, pp. 105-110.
Higgins, K.T. (2005), “Lean builds steam”, Food Engineering: The Magazine for Operations and Manufacturing Management. Available at: https://www.foodengineeringmag.com/articles/84465- lean-builds-steam (accessed April 23 2020).
Ismyrlis, V., and Moschidis, O. (2013), “Six Sigma’s critical success factors and toolbox”, International Journal of Lean Six Sigma. Vol. 4, No. 2, pp. 108-117.
Jeyaraman, K., and Teo, L.K. (2010), “A conceptual framework for critical success factors of lean Six Sigma”, International Journal of Lean Six Sigma. Vol. 1, No. 3, pp. 191-215.
Jirasukprasert, P., Garza-Reyes, J. A., Kumar, V., and Lim, M. K. (2014), “A Six Sigma and DMAIC application for the reduction of defects in a rubber gloves manufacturing process”, International Journal of Lean Six Sigma, Vol. 5, No. 1, pp. 2-21.
Lee-Mortimer, A. (2006), “Six Sigma: a vital improvement approach when applied to the right problems, in the right environment”, Assembly Automation, Vol. 26 No. 1, pp. 10-17.
Mehrjerdi, Y.Z. (2011), “Six–sigma: methodology, tools and its future”, Assembly Automation. Vol. 31, No. 1, pp. 79-88.
Montgomery, D.C., and Woodall, W.H. (2008), “An overview of six sigma”, International Statistical Review, Vol. 76, No. 3, pp. 329-346.
Montgomery, D.C., and Runger, G.C. (2010), “Applied statistics and probability for engineers”, John Wiley & Sons.
Moore, D.S., McCabe, G.P. and Craig, B.A. (2009), Introduction to the Practice of Statistics, 7th ed.,W.H. Freeman and Company, New York, NY.
Nabhani, F., and Shokri, A. (2009), “Reducing the delivery lead time in a food distribution SME through the implementation of six sigma methodology”, Journal of manufacturing technology Management, Vol. 20, No. 7, pp. 957-974.
Pande, P., Neuman, R., and Cavanagh, R. (2001), “The Six Sigma way team fieldbook: An implementation guide for process improvement teams”, McGraw Hill Professional.
Psychogios, A.G., Atanasovski, J. and Tsironis, L.K. (2012), “Lean Six Sigma in a service context: a multi-factor application approach in the telecommunications industry”, International Journal of Quality & Reliability Management, Vol. 29, No. 1, pp. 122-139.
Pyzdek, T., and Keller, P.A. (2003), “The Six Sigma Handbook: A Complete Guide for Green Belts, Black Belts, and Managers at All Level”, New York: McGraw-Hill
Pugna, A., Negrea, R. and Miclea, S. (2016), “Using six sigma methodology to improve the assembly process in an automotive company”, Procedia-Social and Behavioral Sciences, No. 221, pp. 308-316.
Raimundo, L.M.B., Batalha, M.O., and Torkomian, A.L.V. (2017), “Dinâmica tecnológica da Indústria Brasileira de Alimentos e Bebidas (2000-2011)”. Gestão & Produção, Vol. 24, No. 2, pp. 423-436.
Salah, S., Rahim, A., and Carretero, J. (2010), “The integration of Six Sigma and Lean management”, International Journal of Lean Six Sigma, Vol. 1 No. 3, pp. 249-274.
Seow, C., Knowles, G., Johnson, M., and Warwood, S. (2004), “Medicated sweet variability: a six sigma application at a UK food manufacturer”, The TQM Magazine, Vol. 16, No. 4, pp. 284-292.
Snee, R.D. (2010), “Lean Six Sigma – getting better all the time”, International Journal of Lean Six Sigma, Vol. 1 No. 1, pp. 9-29.
Voss, C.; Tsikriktsis, N.; Frohlich, M. (2002), “Case research in operations management”, International Journal of Operations Management, Vol. 22, No. 2, pp. 195-219.
Womack, P.P., Jones, D.T., and Ross, D. (1990), “The Machine that Changed the World”, New York: Macmillan.
Womack, J.P., and Jones, D.T. (1996), “Lean Thinking: Banish Waste and Create Wealth in Your Corporation”, New York: Simon & Schuster.
Yin, R.K. (2009), “Case study research: design and methods”, 4th edition. Applied social research methods series, 5. SAGE Publication.
Lean Six Sigma, DMAIC, Operational Excellence, Food Industry.