Applying Lean Six Sigma Methodology to Improve Productivity: Case Study at a Mooncake Production Enterprise

Abstract

This study aims to apply the Lean Six Sigma methodology to reduce defect rates at a mooncake production company. The study reveals that the highest defect rate, recorded at 3.78%, occurred during the semi-finished product shaping stage. The research uses the Pareto chart to analyse the causes of the defects, while the Delphi method and cause-and-effect diagrams are applied to identify the root causes of the primary defects. To enhance the process, the research team adjust the technical specifications of the shaping mould and employ a t-test to evaluate the statistical significance of the improvement results. As a result, the defect rate was significantly reduced from 3.78% to 3.12%. This improvement leads to an increase in the Sigma level from 3.28 to 3.36, resulting in annual cost savings of USD 6,018 for the company. Looking ahead, the DMAIC methodology can be further applied to address other defect rates within the mooncake production process.