Lean and Six Sigma Applications in Tofu Production

The global tofu market size was valued at USD 2.97 Billion in 2024.* We’ll look at Lean and Six Sigma applications in the production of tofu and finish with a video of how tofu is made.

*Source

Using the Six Sigma Method in Tofu Production

In a paper titled “Product Quality Development Analysis with Six Sigma Method: Case of SME Tofu Production in Indonesia” authors L. Sanny, Scherly Novita, and S. Novela apply Six Sigma in order to reduce the defects in tofu production.

The paper includes:

Accumulation Data of Defect Product
Pareto Chart of Defects
Cause and Effect Diagram
Post Study Recommendations

You can read the paper here.

Lean Manufacturing for Improving Tofu Production Efficiency

In a paper titled “Lean Manufacturing to Improve the Efficiency in A Small and Medium Enterprise: Case in Tofu Production Processes” authors Sri Hartini and others discuss the identification of wastes in tofu production and suggested improvements.

The paper includes:

Input-output Diagram of Tofu Production Process
Initial Layout of Production Area
Efficiency Tabulation
Current State Value Stream Map
Failure Mode and Effects Analysis
Fishbone Diagrams
- Over-processing Waste at Filtering Process
- Transportation Time Waste at Pressing or Molding Process
- Waiting Time Waste at Boiling Process
Proposed Production Area Layout Based on 5S Approach
Proposed Production Area Layout Based on 5S Approach and Mechanization
Future State Value Stream Map
Comparison of Efficiency Before and Expectation After Repair

You can access the paper here.

Evaluation Defects in Tofu Production

In a paper titled “Integrating Seven Tools and Kaizen Approach in Evaluating Defects on Tofu Production Process” authors Ahmad Dziky Wardana and Nina Aini Mahbubah

The paper includes:

Pictures of Mushy, Cracked, and Crushed Tofu
Number and Types of Defects
Production Process Flow Chart
Histogram of the Number and Types of Defects
Pareto Chart of Defects
Total Defects by Production Quantity
Ishikawa Diagram for Crushed Tofu
Results of Improvement Analysis with Kaizen Five-M Checklist
Improvements Plan with 5W and 1H
Current Conditions of 5S

You can read the paper here.

[Citation: Wardana, A. D., & Nina Mahbubah. (2022). Integrating Seven Tools and Kaizen Approach in Evaluating Defects on Tofu Production Process. Jurnal E-Komtek, 6(1), 101-113. https://doi.org/10.37339/e-komtek.v6i1.879]

Assessing the Use of 5S in a Tofu Factory

In a paper titled “Assessment of 5S at Tofu X Factory” authors Fitria Noor Aida and others discuss the use of 5S in order to increase productivity in a tofu factory.

The paper includes: