The global pasta market size was valued at USD 71.50 billion in 2024 and is projected to grow from USD 75.50 billion in 2025 to USD 108.67 billion by 2032.* We’ll look at applications of Lean and Six Sigma in the pasta industry and finish with a video of a large pasta plant producing 1400 tons per day.

*Source: https://www.fortunebusinessinsights.com/pasta-market-102284

Implementation of Quality Tools in Stuffed Pasta Industry

In a case study titled “Implementation of quality tools in a stuffed pasta industry” authors Jiuliane
Martins da Silva and others discuss the promotion of improvements through the implementation of a
combination of quality tools from Lean and Six Sigma.

The study includes:
 Flowchart of the Company& Production Process
 Percentages of Compliances Before and After Implementation of the 5S Program
 Non-conformities Found in the Industry and Corrective Measures Based on the 5S Program
 Percentage of Non-conformities About Good Manufacturing Practices
 Industry Non-conformities Regarding GMP During the Diagnostic Stage and the Corrective
Measures Implemented

 5S Program Non-compliance Cause-Effect Diagram

You can read the study here:
https://www.researchgate.net/publication/343084248_Implementation_of_quality_tools_in_a_stuffed
_pasta_industry

Value Stream Mapping Techniques in Pasta Manufacturing

In a case study titled “Elimination of Wastes in Pasta Manufacturing using Value Stream Mapping
Techniques: A Case Study of Golden Pasta Company, Lagos” authors Mohammed Tiamiyu, Mauton
Gbededo and Peter Farayibi discuss the use of Value Stream Mapping to eliminate wastes in pasta
manufacturing.

The study includes:
 Product-Sales Matrix for Product Type
 Customer Sales for Pasta brands from 2012-2016
 Production Lines by Number of Breakdowns
 Customer Requirements for FLG3 Production Line
 Total Time Observation Records for Spaghetti Manufacturing processes at FLG3
 KPIs for Golden Pasta VSM Implementation
 Completed Current VSM with Data Boxes and Timeline
 Proposed Future VSM with Data Boxes and Timeline

Copy and paste the following link into your browser to access the case study.
https://www.ijert.org/research/elimination-of-wastes-in-pasta-manufacturing-using-value-stream-
mapping-techniques-a-case-study-of-golden-pasta-company-lagos-IJERTV6IS110192.pdf

Using Lean Manufacturing to Increase Pasta Packaging Line Capacity

In a short paper titled “Increase of Packaging Line Capacity using Lean Manufacturing” authors Pedro
Rosado Pagán and Carlos González discuss the use of Lean Manufacturing to increase packaging capacity in a Pasta plant.

The paper includes:
 Project Charter
 Printing Process SIPOC
 Processing Time Per Each Packaging Step
 Packaging Downtime Per Process Step
 Average Boxes Output Per Hour
 Packaging Steps Downtime
 New Average Boxes Output Per Hour

You can read the paper here:

https://prcr.cobimet.org/server/api/core/bitstreams/7e9d18d1-e586-4120-8d41-
e802644bb311/content

Producing 1400 Tons of Pasta Per Day

See how Barilla makes 1400 tons of pasta per day in the world’s largest pasta plant in this video from
Insider Food.

You can watch the video here: https://www.youtube.com/watch?v=5J43R-DDmNc