Title: Scrap reduction in confectionery plant through Lean Six Sigma

Authors: Aravindh Kumaran Lekshmana Perumal; Sivakumar Kirupanandan; Gangesh Palani Gopinath

Addresses: Loyola Institute of Business Administration (LIBA), Loyola College Campus, Chennai – 600 034, India ' Loyola Institute of Business Administration (LIBA), Loyola College Campus, Chennai – 600 034, India ' Loyola Institute of Business Administration (LIBA), Loyola College Campus, Chennai – 600 034, India

Abstract: The application of Lean Six Sigma (LSS) in scrap reduction of confectionery plants is demonstrated with a case study in this paper by identifying the possibilities of reducing scrap thereby improving efficiency of the continuous process. This study adopted a cross-sectional study of a complete cycle of value stream mapping (VSM) – define measure analyse improve and control (DMAIC), the LSS approach by observing the plant over months. This study was conducted in a unique production company to explore the scrap reduction in manufacturing chocolates using LSS approach. The outcome of the study demonstrates that the scrap has been reduced from 30 kg to 2.5 kg led to significant savings for the company through obtaining correct machinery setting by using predictive analytics. The results of the study present the major contributors and success contributors that future researchers and consultants can use to eliminate scrap specifically in the continuous process industry.

Keywords: Lean Six Sigma; LSS; value stream mapping; VSM; DMAIC; scrap reduction; confectionery plant; food processing industry.

DOI: 10.1504/IJSSCA.2025.145619

International Journal of Six Sigma and Competitive Advantage, 2025 Vol.15 No.3, pp.266 - 290

Received: 22 Mar 2024
Accepted: 24 Sep 2024
Published online: 09 Apr 2025 *

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