The production of dairy products is made up of manufacturing processes. Therefore, the Six Sigma DMAIC methodology can be used for continuous improvement.
We’ll take a look at three case studies of the DMAIC application in the dairy industry: two for milk production, and one focusing on yogurt manufacturing. Finally, we’ll refer to a video of a milk production line.
DMAIC Applied to Improving Efficiency of Milk Filling
In an article titled “Improving Efficiency of the Filling Line in a Dairy Industry,” the authors Eduardo Moró Pérez and José A. Morales discuss how DMAIC was applied to improve the efficiency of the filling line.
Their project charter is shown below.
Next, their SIPOC diagram.
And the subsequent Cause and Effect Diagram.
As stated in the project charter, one goal was to reduce the number of non-programmed stops.
You can access the article here to read the details of their case study.
Using DMAIC to Reduce the Chilling Cost of Milk
In an article titled “Energy Saving Using DMAIC Approach in Milk Plant -A Case Study”, the authors Sunil Dutt Sharma and Harwinder Singh cover the DMAIC methodology used to reduce the chilling cost for milk.
The goal of the project was to reduce electricity consumption and save water.
During the Measure Phase, they produced the following Cause and Effect diagram.
After the Analyze, Improve, and Control Phases they were able to reduce the refrigeration and chilling cost of Rs. 0.57 per liter to Rs. 0.39 per liter.
You can access the case study here.
DMAIC Used to Optimize the Level of Key Factors Affecting Yogurt Acidity
In an article titled “Application of Six-Sigma DMAIC Methodology in Plain Yogurt Production Process”, the authors Saeid Hakimi, Seyed Mojib Zahraee, and Jafri Mohd Rohani, cover the DMAIC phases for their case study.
Here is their summary.
Deﬁne: Yogurt production process was described and the CTQ characteristic for
yogurt production process according to VOC was deﬁned as the rate of acidity.
Measure: The pH values were chosen as the CTQ functions for evaluating the rate of
the acidity in yogurt production process. In addition, ﬁve potential control variables
that inﬂuence the pH values of the yogurt were characterized.
Analyze: DOE was used to detect signiﬁcant factors inﬂuencing the pH values of
Improve: The optimum settings of key process parameters were determined through
usage of desirability function method.
Control: Improved processes were standardized in the real production environment
and integrated into quality management system
And the Cause and Effect diagram for factors affecting the yogurt quality.
The article gives a detailed explanation of the experimental design that was used to determine the key factors and their optimal levels.
You can access their article here.
A Complete Milk Production Line Video
Finally, let’s see an actual milk production line in operation from SMF Germany.
You can view the video here.