DMAIC Project: Reducing Salt Mixing Errors in Production by 50%

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Baseline (Define)

The project improved the salt mixing more evenly during the spice mixing phase. The customer is the consumer, but also the subsequent ripening stage of the product, which is affected by the salt content of the product. The process had to be improved because it had been observed that the salt was not mixed evenly and complaints had been received. The aim was to reduce the number of mixing errors by at least 50%. An error is defined as a deviation of a certain percentage of salt from the target value.  

Process performance at the beginning (Measure)

Initially, about 20% of the samples taken at random points went outside the limits. This was higher than expected. The data made it possible to identify the impact of different products, measuring agents and mixing methods, allowing measures to be quickly targeted to the right place.

Improvement measures (Analyze & Improve)

The measurements showed that the main cause was uneven dosing. The mixer was not able to mix the salt evenly if the salt was unevenly distributed in different parts of the mixer. A new dosing method was designed into the process.

Results (Control)

The dosage change reduced the number of out-of-limit results by 84%. The results are maintained through work practice changes and regular salt measurements. The work provided new information on mixer performance and mixing method. It was also learned how even small changes can have big effects.  

This project is an example of a Lean Six Sigma Green Belt training exercise project that the participant did as part of the training and Green Belt certification.

If you are interested in learning how to improve your processes with Lean Six Sigma, and earn your Green Belt certification at the same time, check out the training at the link: Green Belt training.

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