As of 2024, the global chocolate industry is worth $127.9 billion USD. See the source for current
chocolate statistics (Market Data 2024).* We’ll look at several applications of Lean and Six Sigma in the chocolate industry and finish with a video of how chocolate is made from the beans.
*Source

Six Sigma Used to Determine Cocoa Powder Quality
In a paper titled “Determination of Cocoa Powder Quality Produced by Small-Medium Enterprise Using Six Sigma Analysis” authors Hendy Firmanto, Yesi Kumalasari and Zikil Muarrofah discuss the cocoa process production performance through Six Sigma analysis of the product.

The paper includes:

  • Pareto diagram of non-conformity cocoa powder product
  • Ishikawa diagram of cause-effect of cocoa powder production

Click on following link to download a copy of the paper.

Using the DMAIC Method to Improve the Quality of Chocolate Production

In a paper titled “Improving the Quality of the Chocolate Production Process at Wahana Interfood
Nusantara Company Using DMAIC Method” authors Doffikar Batuta and Mohamed Abd Rahman discuss their study to identify the effects of implementing the DMAIC methodology in improving the quality of the chocolate production process.

The paper includes:

  • Production Data of White Couverture Chocolate
  • Pareto Chart of Types of Defects
  • Fishbone Diagram of Types of Defects

Use the following link to read the paper.

Reducing the Production Cost of Cal Poly Chocolates Through the DMAIC Approach

In a Bachelor’s thesis titled “A Study into the Production Efficiency of Cal Poly Chocolates” author
Fernando Calderon discusses his project to identify ways to reduce the production cost of Cal Poly
Chocolates through the DMAIC approach.

NOTE: Cal Poly Chocolates was started in 2000 by now retired Food Science and Nutrition Faculty
member Dr. Tom Neuhaus. Student employees learn about the science and art of chocolate making and some of the tools and equipment used to make all things chocolate by producing chocolate bars for sale.

The thesis includes:

  • Current State Line Balance
  • Cost Model for Support vs. No Support
  • Current State Flow Process Chart
  • Current State Metrics
  • FMEA of Production
  • Flow Wrapping Setup Checklist
  • Flow Wrapper Troubleshooting Process Chart
  • Future State Line Balance
  • Current vs Future State Metrics and Savings

Copy and paste the following link into your browser to read the thesis.

Reducing the Rework in Milk Chocolate Production
In an article titled “Implementation of Six Sigma in a Chocolate Industry: A Case Study of Amul Dairy”, Mavank Dev Singh and other authors document a case study applying Six Sigma to milk chocolate production.

The article includes:

  • Pareto Chart of Chocolate Type
  • Reason for Rework Diagram
  • Macro Map

Copy and paste the following link into your browser to access the article.

Applying Lean Tools in a Major Chocolate Plant

In a short case study titled “Lean toolbox for seasonal process industries: A nougat fabrication case
study” authors M. Tanco and others discuss the application of Lean tools to making nougat in a major
chocolate plant.

The case study includes:

  • Current Value Stream Map
  • Future Value Stream Map

You can access the case study here:

Making Chocolate
See how chocolate is made in this video from the Science Channel.
You can watch the video here.