The global frozen food market size is expected to reach USD 504.41 billion by 2030 from 265.13 billion in 2022.* We’ll look at applications of Lean and Six Sigma in the frozen food industry and finish with a video on the history of frozen foods and the role of Birds Eye.

*Source

Six Sigma Applied to the Analysis of Defects in Frozen Fish Steak Processing

In a case study titled “Defects Analysis Of Frozen Fish Steak Processing Using Six Sigma: A Case Study” authors A. Poernomo, N. Ferawati and R. B. S. Salampessy discuss the use of Six Sigma methodology to analyze frozen fish steak processing defects.

The case study includes:

  • Frozen Fish Steak Process
  • Observed Defects and CTQs
  • Pareto Chart of Defects
  • Cause and Effect Diagrams
    • Undersize Fish
    • Quality Deterioration

You can read the case study here. 

[Citation: A Poernomo et al 2021 IOP Conf. Ser.: Earth Environ. Sci. 919 01203]

Using Six Sigma Methods to Reduce the Defects in the Production of Frozen Chicken Nuggets

In a paper titled “Analysis of Quality Control of Chicken Nugget Products by Using Six Sigma Method at PT. XYZ” authors Neldo Irawan, Anny Ratnawati, and Salsa Dilla discuss the use of Six Sigma methods to improve the production of frozen chicken nuggets. PT. XYZ is a food company engaged in the field of food processing, especially frozen processed food.

The paper includes:

  • Chicken Nugget Defect Types
  • CTQ Process of Making Chicken Nuggets
  • Process Capability for Making Chicken Nuggets
  • Main Causes of Defective Products
  • Process Improvement Strategy
  • Control Measures

You can read the paper here. 

[Citation: Neldo Irawan et al 2021 J. Phys.: Conf. Ser. 1764 012210]

Apply Six Sigma in Frozen Small Custard Bun Production

In a paper titled “Applying Six Sigma To Manufacturing Processes In The Food Industry To Reduce Quality Cost” authors Hsiang-Chin Hung and Ming-Hsien Sung discuss the use of Six Sigma to reduce defects in frozen small custard bun production.

The paper includes: 

  • Pareto Charts
    • Product Type Defects
    • Customer Complaints
    • Bun Type
  • Project Selection Tree Diagram
  • Process Flow for Custard Bun
  • Fishbone Diagram for Shrinkage
  • Attribute Agreement Measurement Study
  • Experimental Design Results for Shrinkage
  • FMEA and Remedial Actions
  • Counteraction Plan for Shrinkage

You can read the paper here. 

 

Morrison Lamothe Canada’s Largest Producer of Frozen Entrees and Dinners

An article titled “Cold Branded” in Industry Today discusses Morrison Lamothe Canada’s single largest producer of frozen entrees and dinners.

Morrison Lamothe has three world-class, technologically advanced food processing facilities in the Toronto area, all using Lean manufacturing processes and Six Sigma practices.

On its website, the company says 

Morrison Lamothe applies Lean Manufacturing and Six Sigma principles to many of its operating and manufacturing processes. We provide customer value with cost-effective solutions delivered in a quality-driven environment. Operational excellence is achieved by:

  • Focusing on the challenges faced by customers and providing them with solutions;
  • Turning feedback into actions that drive improvements in the way we service customers;
  • Ensuring consistency in operations; 
  • Striving for continuous improvement while reducing waste.

You can read the article here.

Frozen Foods From Its Beginnings to Today

See the history of frozen foods and the contributions of Birds Eye in this video from Insider Business

You can watch the video here.