Deconstruction of Operational Variability in Biomass Production: An Application of Lean Six Sigma and System Dynamics

Purpose: This study seeks to optimise key production parameters for biomass pellets by employing Lean Six Sigma (LSS) alongside dynamic system simulation. Emphasis is placed on fine-tuning moisture content, durability, and pellet diameter to meet international quality standards and performance operational. Methodology/Approach: The research integrates DMAIC methodology with dynamic simulation modelling, analysing and optimising drum speed, material feed rate, and drying temperature via factorial design and system dynamics. Findings: Implementing LSS markedly reduced moisture variability, hitting a stable mean of 9.446% and cutting defects down to 59,000 PPM. Durability saw a notable lift from 91.976% to 95.896%, with defects slashed by 80%. Pellet diameter was fine-tuned from 7.241 to 7.051 mm, bringing defects down to 45,000 PPM. The results meet international standards and show improvements in process performance. Research Limitation/Implication: The study is limited to one biomass site, focusing on key quality parameters. Future research could assess scalability and suitability across other renewable energy sectors. Originality/Value of paper: This research highlights the novel integration of Lean Six Sigma and dynamic simulation in biomass pellet production, providing a robust framework for quality and operational stability in energy.