This document provides an overview of Six Sigma concepts and their potential applications in the dairy industry. It discusses the history and approaches of Six Sigma, including the DMAIC and DMADV methodologies. Two case studies are presented that demonstrate how Six Sigma was used to improve the yogurt production process and reduce variations in a packaging process. The advantages of Six Sigma for the dairy industry include reducing costs, improving quality, enhancing productivity and reliability, and improving customer loyalty. The document concludes that Six Sigma provides a systematic approach to problem solving and its flexible methodology can be applied at various stages of dairy production and distribution.

1. Six Sigma Concept: Applications
and Advantages in Dairy Industry
Submitted By:
Nandita Das
Dairy Chemistry (Ph.D)
1

2. CONTENTS
Introduction
History
Approaches Of Six Sigma
Levels Of Six Sigma Implementation
Applications Of Six Sigma
Potential Applications Of Six Sigma In Dairy Industry
Case Studies
Advantages Of Six Sigma In Dairy Industry
Conclusion
2

3. Introduction
What is six sigma?
It is a systematic and organized technique to improve the strategic process, new product development, service that
focus on scientific and statistical methods to make considerable reductions in customer determined defect rates.
 This increase in performance and decrease in process variation.
 It leads to defect reduction and improvement in profits, employee morale and quality of product.
(Linderman et al., 2003)
(Anbari, 2002; Schroeder et al., 2008)
Six Sigma is a
top-down solution to
help organizations
3

4. Objectives of 6σ :
• Improve customer satisfaction (Internal and External)
• Improve the quality of product and service
• Reduce the process cycle time
• Overall cost saving up to 30%
• Development of staff skill
Where it is used:
• Manufacturing and service industries
• Sales and Marketing
• Accounting and Financing
• Product designing
• Supply chain management
Financial
Bank of
America
GE Capital HDFC HSBC
American
Express
Hospitality ITC Hotels GRT Hotels
Apollo
Hospitals
Manufacturing
Johnson
and
Johnson
Motorola Nokia Nestle Samsung
Telecom
Bharti
cellular
Vodafone Tata
IT Wipro Infosys Microsoft TCS
(Zu et al., 2008; Zahraee, 2016)
(Sharma et al., 2013)

5. History
• Francis Galton conceived of a
measure to quantify normal
variation: the standard deviation
1860s
• Walter A. Shewhart introduces
the control chart and the
distinction of special vs. common
cause variation as contributors to
process problems
1924 • Bill Smith – then a senior
scientist at Motorola –
introduced the concept of Six
Sigma to standardize the way
defects are counted
1986Father of statistical quality
Father of 6σ
(Anbarai, 2002; Schroeder et al., 2008)
5

6. Define
Measure
AnalyzeImprove
Control
Approaches Of Six Sigma
Define
Measure
AnalyzeDesign
Verify
DMAIC APPROACH
This is organizational based
DMADV APPROACH
This is based on customer needs
and satisfactions
(De Mast and Lokkerbol, 2012; Wright and Basu, 2008)
6

7. 1. Define: to clarify the problem and analyze the
benefits.
2. Measure: to assess the current situation and
translate the problem in to a measurable
parameter (CTQ).
3. Analyze: to determine the effect of factors
and causes that affect the CTQ’s behavior.
4. Improve: to improve the CTQs performance
by designing and implementing the
adjustments to the process.
5. Control: to control the system and
adjustment of the process management
forsustainable improvements.
1. Define design goals that are consistent with customer
demands and the enterprise strategy.
2. Measure and identify CTQs (characteristics that are Critical
To Quality), product capabilities, production process
capability, and risks.
3. Analyze to develop and design alternatives, create a high-
level design and evaluate design capability to select the
best design.
4. Design details, optimize the design, and plan for design
verification. This phase may require simulations.
5. Verify the design, set up pilot runs, implement the
production process and hand it over to the process
owners.
DMAIC
This approach is undertaken to improve existing
business process
DMADV
This approach is undertaken when there is a need to create
new design or product.
DMADV is also known as DFSS, "Design For Six Sigma
7
(Srinivasan et al., 2014; Antony et al., 2012)

8. Levels Of Six Sigma Implementation
Yellow Belt
Champions undergo five days of
training and are taught how to
manage projects and act as
advisors to various project teams
Green Belt
They undergo two weeks of
training that includes project-
oriented tasks. They act as team
members to the Six Sigma
project team. Their cooperation
and involvement is necessary for
projects success
Black belt
They receive four weeks of
trainings and are directly
involved in the implementation
of Six Sigma Projects. They are
the project leaders and go
through in-depth training on Six
Sigma approach and tools and
work full time on the project.
Master Black Belt
These are the people who
conduct Six Sigma Training and
also have on the job training and
experience
(Su and Chou, 2008)
8

9. 9
They have got the prestigious
achievement of SIX SIGMA
RATING because of their
percentage of correctness which
is just perfect up to 99.999995
i.e. six decimals or more than
that. Not many of the topmost
companies are even near to it.
This is simply incredible!
Error Rate
1 in 16 million transactions
(Vashisht, 2018)

10. CASE STUDIES
1. Application of Six-Sigma DMAIC methodology in plain yogurt production
process
2. Curbing variations in packaging process through Six Sigma way in a
large-scale food-processing industry
10

11. Case Study 1 Purpose
• To concentrate on quality
improvement in plain yogurt
production process at company A
through adjusting the factors affecting
the acidity of the yogurt and
determining the optimal level of these
factors.
Design/approach
• DMAIC
• DOEs tool
Findings
• Incubation time and fat% are
significant factors affecting acidity
development
(Hakimi et al., 2017)
Effects of inoculation
rate and incubation
temperature on
structure and physical
properties of yogurt
gels were investigated
by using DOE
Optimal settings of
significant factors for
achieving the
targeted pH value
based on customer
perspective using
desirability function
The results of study
are implemented into
the real production
environment
Approach
11

12. 12
Define:
SIPOC diagram
To identify the process outputs and
the customers of those outputs so
that the voice of the customer can be
obtained
1
Brainstorming was executed by the
team members based on 5M criteria
(man, machine, material, method and
measurement) and environment to
specify all possible factors affecting
quality of yogurt production process
Measure:
Cause and effect diagram
2
(Hakimi et al., 2017)

13. 13
Possible process factors affecting pH values of yoghurt
S. No. Process factors Classification as per 5M
1 Skim milk powder Material
2 Heat treatment Method
3 Inoculation temperature Measurement
4 Oxygen concentration Machine
5 Incubation temperature Measurement
6 Concentration of starter culture Material
7 Incubation time Man
8 Fat% Material
9 Milk composition Material
Process factors settings
S. No. Process factors Label Low level setting High level setting
1 Skim milk powder (g/100 g) A 0.5 4.5
2 Inoculation temperature (ºC) B 50 55
3 Incubation temperature (ºC) C 40 44
4 Incubation time (hour) D 4 12
5 Fat percentage (%) E 1.5 3.5 (Hakimi et al., 2017)
Analyze:
Used DOE to
analyze most
possible factors
influencing the pH
values of yogurt.
3

14. 14
2(5-1) Design for the
pH experiments
First order regression
model is developed by
Minitab software
Main effects plot for pH (Hakimi et al., 2017)

15. Improve:
• The result of the analysis showed that incubation time (D) and fat percentage (E) were significant factors;
in contrast, skim milk powder (A), inoculation time (B) and incubation temperature (C) were not
significant.
• Increasing or decreasing the level of significant factors has high impact on pH value; on the other hand,
the same is not true for non-significant factors and analysis of them during optimization process is not
essential.
(Hakimi et al., 2017)
• Consequently, the pH values
in the range of the
specification limits, 4.4-4.6,
were satisfactory and the pH
values less than 4.4 or higher
than 4.6 were not
appropriate.
• The optimal settings for
control variables were
obtained, considering the
acceptable specification limits
for pH value, through usage
of desirability function
method.
4

16. 16
• The results showed that incubation time and fat percentage were significant factors on pH values of yogurt, and
the optimum settings for these factors were defined as 12 h for the incubation time and 1.5 per cent for the
fat%. Furthermore, implementation of improved processes in yogurt production line resulted in achieving the
acceptable pH values of yogurt within the range of 4.2 to 4.4 in accordance with customer’s preferences.
• In this case study, the Six Sigma approach provided the company with an example of the advantages of dealing
with a problem systematically. This case can prompt managers of the company to apply Six Sigma method to
address complicated problems in other processes, where causes particularly are not clear.
Control
• To gain the aim, necessary modifications and revisions in the process procedures and
control plans were performed to provide consistency and reduce process variation and
mistakes.
• For example, the CTQ function, pH value and the level of control variables were attached
to the audit checklist to conduct verifications within the audits.
• Statistical process control charts are used to monitor a process to determine the probable
variations that happen over time.
• Reaction plans were organized to assist operators in taking actions in case any deviation
or shifts from acceptable range of pH values and optimal controllable variables into
control charts occurred.
5
(Hakimi et al., 2017)

17. Case Study 2
17
Purpose:
Implementation of DMAIC on one of the chronic problems,
variations in the weight of milk powder pouch.
(Desai et al., 2014)
Define
• The problem statement is ‘‘To reduce the
variations in the weight of 1 kg milk powder
pouch’’.
Measure
• Process of filling up 1 kg milk pouch was
thoroughly observed with a view to examine the
deviation pattern, if any. For calculation of
baseline sigma level after few trials the data were
collected for 25 samples having subgroup size 36.
1
2

18. 18
Tools and technique adopted to uncover the root causesAnalyze
• 1. Open root cause analysis—cause-effect diagram
• 2. Narrow root cause analysis—multivoting and Pareto charting
• 3. Close root cause analysis—five-why analysis
3
Cause-effect diagram
Probable Causes
• Wear and tear of auger screw and tube
• Weighing machine calibration
• Vibration in filling machine
• Density variation
• Changeover of product
• Stickiness of powder
After multi-voting results
(Desai et al., 2014)

19. 19
Improve:
Based on the root causes and the answers emerged from the five-why
techniques, the following improvement measures were worked out.
• Alignment between augar screw and tube assembly should be checked
every time when product changeover occurs.
• Air conditioning system must be able to meet the condition requirement
of air in the room.
• Calibration frequency of weighing machine should be at least twice per
month.
• Design of feedback loop of control system such that system response time
reduced to minimum possible Level
• Planning for changeover of product should be such that it takes minimum
time to set the machine for new product and maximize the machine
availability time.
• Maintenance should be planned during product changeover.
Control:
• Periodic review of the different measures
recommended in improve phase.
• Application statistical quality control charts,
like X-bar and S-chart to check the
consistency of the process maintaining
targeted sigma level.
Conclusion:
• The implementation of DMAIC methodology resulted in understanding the problems from all aspects, qualitatively as well as
quantitatively, and laying out the improvements through effective analysis of the roots of the problem.
• The problem of variations in the weight of 1 kg milk powder pouch was addressed satisfactorily and the rejection rate was
brought down to 50 %.
• The potential of improvement thus appears significant if the same improvement methodology can be applied to packaging
process of other varieties. The cumulative savings can be of very large magnitude justifying the application of Six Sigma
improvement methodology across the unit on different packaging process.
4
5
(Desai et al., 2014)

20. Advantages of Six sigma in Dairy Industry
20
Reduction in
distribution costs
Enhancing reliability of
dairy products delivery
Reducing or Preventing
wastage in case of
perishable items
Improving delivery
vehicle utilization
Improving adherence to
schedules at delivery
and collection points
Reduction in
Maintenance
costs/produced units
Enhancement in
Productivity
Reduction in machine &
plant maintenance cost
Reduction in processing
machinery downtime
Enhancement in quality
of packaging
Improved customer
loyalty
Time management
Reduced cycle time Employee motivation Strategic planning
Supply chain
management
(Vashisht, 2018; Kovach and Chu, 2011; Zhen, 2011; Tylutki and Fox, 2002)

21. Other applications Of Six Sigma
Recentapplications
Improving health effects in caring institutions
Reducing defects of a grinding process
Enhancing the efficiency of IT help-desk service
Improving the production planning procedure’s performance
Improving the quality in manufacture of automotive products
Improving the quality of medical wire manufacturing process
(Chen et al., 2011; Gijo et al., 2011; Leao et al., 2011; Chang et al., 2012; Antony et al., 2012; Nepal et al., 2013)
21

22. CONCLUSION
 Six Sigma implies three things: statistical measurement, management strategy, and quality culture.
 It gives multidirectional benefits in relatively shorter duration of time.
 The list of benefits of Six Sigma is endless including better understanding of changing customer requirements,
improvement of quality and delivery, reduction of waste, reduction of cost, development of robust products and
processes, enhancement of competitive position, and sustained competitive advantage through continuous
improvement of all business systems in the organization.
 On the basis of these advantages and flexibility of six sigma, it can be implemented at each and every step in dairy
industry starting from dairy farm till sale of the finished product.
 Six Sigma approach provided the company with an example of the advantages of dealing with a problem
systematically. This case can prompt managers of the company to apply six sigma method to address complicated
problems in other processes, where causes particularly are not clear.
 Six Sigma is not being explored extensively by the Indian dairy industries.
22
TQM
Customer
Focus
Data
analysis
tools
Financial
Mgt
Project
Mgt.
Six
sigma