Production improvement of a food manufacturing process through lean six sigma approach

Mhd Said, Shahidatul Aida (2019) Production improvement of a food manufacturing process through lean six sigma approach. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

The key to a successful company is to emphasize the productivity and quality of the product. Continuous improvement in the quality of the product will surely result in good customer response while increasing productivity. This project is being run at SERIHAS RESOURCES located in the Bandar Baru Bangi, Selangor which produces food products called cookies. The company produces 100 bottles of cookies in 2 days. The use of inventory of large quantities of cookies and irregular production line are among the main problems with no productivity increase. The objective of this study is to identify the delay in production activities in the production process using SIPOC tools and Value Stream Mapping tools. In order to increase productivity, the Lean Six Sigma method has been applied. This method is a Lean-based method that focuses on eliminating waste while Six Sigma focuses on reducing variation by using statistical tools such as DMAIC, which are denoted as Define, Measure, Analyse, Improve and Control. DMAIC is an effective way as a guide to the flow of project design to identify critical issues more efficiently. 7QC tools are used to record data and analyse data. After using this method, the value stream mapping method is used as well as the measurement method for each process run. The next phase of the analysis uses the Value added and Non-value added methods to identify the necessary and non-essential processes in the production line. After analysing, it shows that the time wasted in making cookies and that time has to be minimized because it is a source of no increase in productivity. Next, the improvement phase uses the future value stream mapping method to see the entire production line cycle time in the cookie recovery process. In addition, the new layout suggestions show a simpler and shorter production. The last phase of the proposed control is the standard operating procedure for the company. Resulting in an increase of 50% productivity from 100 bottles of cookies produced to 150 bottles produced. This productivity increase was achieved using the Lean Six Sigma method. In conclusion, this proposal has been proposed to enhance the company's future success.

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