Reduction of sugar loss using lean six sigma tools and dmaic method to increase competitiveness and reduce costs in a soft drink company

Introduction: The Lean Six Sigma method is the integration between Lean Manufacturing and Six Sigma, two methods that have been adding value to the productive processes, generating the best results, because they provide tools to assist in the management of the indicators of the companies that use them. The use of this method in the manufacturing process is a strategic factor for the competitive companies, whose focus seeks to meet the customers with an appropriate cost to the market requirements, considering that the existing processes related to the manufacture of a finished product have their variability. Objective: This study aimed to present the application of Lean Six Sigma tools, describe the use of the DMAIC model and demonstrate its application in the process of syrup and filling of beverage in one of the companies of Simões Group, as well as demonstrate the results obtained with the reduction of production cost by reducing the loss of sugar. Methodology: The technique applied in this study followed the steps of DMAIC methodology, where statistical tools were used to DEFINE the objective, the scope and the main steps of the project and to delimit the problem, to MEASURE the current performance of the process and to reduce the problem area, to ANALYZE the potential root causes and confirm them with data to determine the opportunities for improvement, to IMPLEMENT the process improvements by developing and testing solutions that address the root causes and finally to CONTROL the processes to maintain the gains and the transition to full implementation. Result/Discussion: This project had a team that applying VOC methodologies - Voice of Customer, identification of the Critical Attributes for the Quality of the customer - CTQs (Critical to Quality), Serpent Diagram and SIPOC, were able to collect with the internal customers information about the processes of manufacturing of simple syrup, final syrup and filling of drinks in PET bottles, as well as others related to the theme. Conclusion: It was possible to determine and quantify the main process wastes after the total implementation of the actions proposed by the six sigma team, having reached the objective of this project. By comparing the sugar loss with the previous period measured, the analyzed process reduced the average percentage of losses from 2.02% to 0.07% after the implemented actions. Thus, there was a financial contribution of the project to the company with the average annual production cost reduction on sugar waste from $26,056 to $862, resulting in a loss reduction of $25,194 for the company.