According to the Food and Agriculture Organization of the United Nations, 124 countries produce sugar as of 2022. But it’s used in every country in the world. Lean and Six Sigma help improve sugar production and reduce waste. We’ll look a four applications: two from Indonesia, and one each from Ethiopia, and Thailand. Then we will look at a video of how sugar is made.


Using Fault Tree Analysis, FMEA, and DMAIC to Improve Sugar Production: Indonesia

In a paper titled “Application of FTA and FMEA method to improve sugar production process quality,” authors Jojo Andriana and Sunday Alexander Theophilus Noya discuss the use of Fault Tree Analysis (FTA), FMEA, and DMAIC to reduce defects in sugar production.

The paper includes:

  • Number of Defects due to Wet Sugar and Non-Standard Color over Six Months
  • White Sugar Production over Six Months
  • Fault Tree Analysis for Wet Sugar
  • Fault Tree Analysis for Non-Standard Color Sugar
  • FMEA Form for Sugar Crystal Production
  • Recommended Actions

You can read the paper by clicking on the following link, which will automatically download the paper.


Implementing Kaizen Management Techniques to Improve Sugarcane and Sugar Production: Ethiopia

In a case study titled “The Art of the Kaizen Approach for Sugar Production in Ethiopia: Lessons from the Methara Sugar Factory,” author Asayehgn Desta discusses the use of Kaizen management techniques of the improvement in sugar production.

The study focuses on performance indicators such as

  • Application of the 5S
  • Implementation of Lean Thinking
  • Reduction of Space in the Building
  • Material handling
  • Lowering of scrap rates

The company effectively implemented Kaizen techniques leading to an increase in sugarcane plantation output of 35% and an increase in sugar production of 37%.

You can access the case study here.


Applying Value Stream Mapping to Improve Warehouse Management in Sugar Manufacturing: Thailand

In a case study titled “Lean Warehouse Management through Value Stream Mapping: A Case Study of Sugar Manufacturing Company in Thailand,” authors Panittha Ketchancha, Kitisak Tangchaidee, and Nattapong Kongprasert discuss the application of Lean manufacturing to improve and eliminate unnecessary activities in the warehouse management of sugar manufacturing.

The case study includes:

  • Sugar Packaging Arrangement
  • Warehouse Process Production Steps
  • Current State Value Stream Map
  • New Packaging Arrangement
  • Process Activity Mapping of Sugar Packaging
  • Packaging Arrangement Improvement Process: Before and After Improvements
  • Future State Value Stream Map

After improvements, the total workload decreased from 3.114 minutes to 1.626 minutes, a decrease of 48%.

You can access the case study here by using the following link and choosing “Download PDF.”


Using Value Stream Mapping to Reduce Wastes in Sugarcane Processing: Indonesia


In a paper titled “Production process analysis using value stream mapping at East Java sugarcane industry,” authors D T Setiyawan, P Deoranto, and D Peranginangin discuss the use of value stream mapping to reduce wastes in sugarcane processing.

The paper includes:

  • Process Activity Mapping of White Crystal Sugar Production
  • Activity Time Comparisons: Current and Future States

You can read the paper here.


How Sugar is Made: Costa Rica


See the sugar-making process from start to finish in Costa Rica in a video from Discovery UK.


You can watch the video here.



Discover why more professionals are taking the next step and joining ISSSP! Access the hundreds of interviews, webinars, whitepapers, case studies, and other resources available in our online library.

Learn More Here