Improving cheese production capacity in a dairy company: a Lean Six Sigma approach for enhanced efficiency and performance

Purpose This study aims to optimise cheese production processes in a dairy company, focusing on reducing milk consumption, increasing production capacity and minimising process variability. Design/methodology/approach The define, measure, analyse, improve and control methodology of Six Sigma was carried out in a dairy company. The study analyses variables and operational factors with tools like analysis of variance, fishbone diagrams and brainstorming to optimise cheese production, reduce milk consumption and minimise process variability in a dairy company. Findings Casein content, humidity and fat content were identified as the primary factors influencing cheese weight variability. Redefining milk treatment according to the optimal casein fat content and optimising cheese placement in drying chambers had the most significant effects among the adjustments made. Operational improvements were implemented, including machine angle calibration and conformer size reduction. These improvements resulted in a 6.8% reduction in milk consumption, a 3.3% increase in production capacity and a 32.4% decrease in process variability. Practical implications This study serves as a compelling demonstration of the potential success of Lean Six Sigma (LSS) in the dairy industry, particularly in optimising resource utilisation for maximum yield in mass cheese production. The outcomes of this study have led to reduced costs and increased cheese yield for the company under investigation, offering a valuable reference for improving cheese production efficiency and enhancing overall product quality. Moreover, the findings of this study can be replicated and applied in other segments of the dairy sector, showcasing the broader applicability and benefits of LSS methodologies. Originality/value To the best of the authors’ knowledge, this study represents one of the few instances of applying LSS to a mass-production dairy producer in Portugal. While existing studies on LSS methodologies in the dairy industry have primarily concentrated on optimising cheese yield through variable manipulation, this study extends the application of LSS principles to broader operational enhancements within the mass production context. This study demonstrated the effectiveness of LSS methodologies in achieving operational efficiency and waste reduction in cheese production through operational improvements, quality control and standardised work.