Application of lean six sigma methodology to improve the weight inconsistency problem of coffee powder packaging

Abstract

This paper presents a continuous improvement (CI) project based on the application of Lean Six Sigma (LSS) methodology. This project was carried out at coffee manufacturing industry located in northern area of Malaysia. The focus of this presented CI project is to improve the weight inconsistency problem of coffee powder packaging. The presented CI project was mainly guided with Six Sigma methodology of Define, Measure, Analyze, Improve and Control (DMAIC) steps, and related Lean tools applications. The step of Define summaries the overall view of CI project. In the step of Measure, current level of sigma based on defect per million of opportunities (DPMO) calculation was determined. Initially, 6% of rejected products were recorded, which it presents the sigma level at 3.1. In the step of Analyze, a series of team-based activities towards root cause identification was carried out. It included the applications of cause effect (CE) analysis and possible causes prioritization and close observations on packaging process. In the step of Improve, the related Lean tool was proposed to improve the problem under study. In the final step of Control, related supportive actions were suggested to sustain the effectiveness of the proposed solution. There are fourteen possible causes are initially identified in CE analysis and based on team’s evaluation process of possible causes prioritization four causes are collectively to be the most possible of root cause(s). Three close observation sessions were carried out to finalize the most possible root cause of the problem. Result strongly suggested that the high variation of coffee powder’s size and inconsistency is the root cause. An improvement strategy based on Lean Manufacturing approach called ‘poka yoke’ is proposed. The proposed improvement strategy was then validated based on real packaging process scenario. Result shows that the proposed improvement strategy is significantly effective to solve the problem with 0% of reject product was recorded so far, where it is not only produced the product within the acceptable weight of 215 and 208 grams, but also presents the reduction of weight fluctuation that close to ideal weight of 208 grams.

An Innovative Framework for Quality Assurance in Logistics Packaging

“…Perishable products TTI (time and temperature indicator) [15,[34][35][36][37] Intelligent packaging [28,34,37], packaging with good tightness and closure properties [35], D/2. Weight problem Weight measurement [38,39] Electronic length measuring (LMD) increase sensitivity, replacement [38] Results of the Systematic Literature Research…”

“…The study in [15] also addresses breakage and is therefore included in the A/1 category, as well as in this category because of perishables. -D/2: Weight problem: From a qualitative point of view, weight problems are addressed in [38] for yarn cone packaging. Electronic length gauges are used and a dimensional analysis is performed on the yarn length.…”

Implementation of six sigma approach for increasing quality formal men’s jackets in the garment industry

“…Based on X-bar Control, Six Sigma can keep the process average close to the target by reducing variance and improving quality [13]. The improvement stage is a plan of action to implement quality improvement with the Six Sigma approach after knowing the causes of each type of product defect that is most dominant [14], [15]. An established technique in the context of software production control that is often used with statistical tools that can be measured and targeted in its manufacture is called the Statistical Process Control (SPC) method approach [16], [17].…”

Application Of Lean Six Sigma Methodology In Defect Reduction: A Case Study Of Kalahari Ash Salt Bagging Plant

“…DMAIC is an acronym from the words Define-Measure-Analyze-Improve-Control, according to Deming cycle (Sokovic et al, 2010). DMAIC methodology has been widely used in many process improvement projects with significant success rates (Jirasukprasert et al 2014;Adeodu et al 2020;Aziz et al 2021). Table 1 gives a summary of the methodology as it was followed in alignment with the objectives of this study and the major tools that were used in the different phases of the project (Table 1).…”