Mejora de la trazabilidad y control de calidad en la producción de premezclas de pastelería mediante la metodología six sigma

Abstract

CONDITION FOR PUBLICATION OF PROJECT. This study applies the Six Sigma methodology through the DMAIC cycle to improve process traceability and strengthen quality control in the bakery premix production line. The methodology contemplates the implementation of a record-keeping system to reduce deficiencies in the weighing area during the production of micro-ingredients in a premix. Through the Define phase of the DMAIC cycle, the lack of traceability of inputs was identified as the priority root cause, accounting for 78.99% of the reported incidents. Consequently, the Project Charter established a goal of reducing traceability errors from 10% to 2% within a period of six months. In the Analyze phase, the implementation of a digital tool (Google Lens) was compared with the optimization of manual record-keeping and it was determined that the digital tool presented limitations in not detecting transposed words. The DPMO (Defects per Million Opportunities) calculation yielded a defect rate of 1.232‰, placing the process at a 4 Sigma level. The implementation of manual recordkeeping not only improved process control but was also financially profitable, with an estimated net benefit of $17,380.05 over a 21-month period, justifying the investment and contributing to continuous improvement and the company's profitability. Keywords: Six Sigma, Microingredients, DMAIC, Traceability, DPMO, 4 Sigma, Bakery, Cost-Benefit Analysis.