Poultry consumption around the world falls into two main categories: meat and eggs. There are a variety of birds that are used in the poultry industry: chickens, turkeys, ducks, geese, partridges, pheasants and others. Lean and Six Sigma methods are used to improve production and quality, whether for meat or eggs. We’ll look at several applications from Brazil, US, Palestine, and Indonesia and finish with a video overview of the poultry industry in the United States.


Evaluating The Lean Production System in a Laying Poultry Farm: Brazil

In a paper titled “Lean Production System: Evaluation in a Laying Poultry Farm” authors Eduardo Guilherme Satolo and others discuss their evaluation of the Lean Production System in a laying poultry farm.

The paper includes:

  • Flowchart of Egg Production System
  • Steps for Data Collection
  • Quantity of Eggs Produced: 2010-2013
  • Explanations about the Perceptions of Application Level of Lean Production System Principles
  • Influence of the Specificities on Agribusiness Production System of Laying Poultry

You can read the paper here.


Six Sigma at Perdue

In an article titled “Perdue Finds Success with Six Sigma,” Larry Nagengast discusses how Perdue has applied Six Sigma. In 2021, Perdue Farms, which includes its chicken business, had annual sales of $8 billion.

The issues Perdue managers wanted to address included:

  • Low productivity in the wing cutup department.
  • Reducing errors in inventory tracking.
  • Reducing downtime in the weight/price label department.
  • Improving efficiency in the cutup department.
  • Reducing waste in the breast trimming department.

You can read the article here.


Lean Six Sigma Application in a Poultry Company: Palestine

In a presentation titled “Implementing Lean Six Sigma in the Palestine Poultry Company,” authors Huthaifa Abu Shhade and others present their Lean Six Sigma project.

The presentation includes:

  • Production Process Map
  • Fishbone Diagram for Productivity Requirements Not Met
  • FMEA
  • Data Collection Plan
  • Crusher Machine Production Capacity
  • Pareto Analysis of Defects
  • Reduction of Non-Value-Added Activities
  • Results Before and After Improvement

Copy and paste the following link into your browser to download the PowerPoint presentation.


Six Sigma-DMAIC Applied to Quality Control of Chicken Production: Indonesia


In a paper titled “Strategy for Quality Control of “Ayam Kampung” Production Using Six Sigma-DMAIC Method” authors Rizki Aditama and Tukhas Shilul Imaroh discuss the use of Six Sigma to improve quality.

Note: Ayam Kampung is an Indonesian native chicken.

The paper includes:

  • Production and Defect Results
  • Fishbone for Low Productivity
  • CTQ for Products
  • Pareto Diagram for Defect Criteria
  • Cause and Effect Diagrams
  • 5 Whys + 1 How Table
  • FMEA

You can read the paper here.


An Overview of the Poultry Industry in the United States

Learn the history of the poultry industry in the U.S. in this overview video from Texas A&M University Poultry Science as told by Dale Hyatt, Research Farm Manager, Department of Poultry Science.

You can watch the video here.




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