Lean & Six Sigma initiatives in the food industry
Autor(a) principal: | |
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Data de Publicação: | 2019 |
Tipo de documento: | Tese |
Idioma: | eng |
Título da fonte: | Repositório Institucional da UFSCAR |
Texto Completo: | https://repositorio.ufscar.br/handle/ufscar/12061 |
Resumo: | Food industry is an important sector that generates significant economic benefits. However, it is an industry that faces many challenges, due to the demanding market that requires a wide range of products, with short delivery times, frequent deliveries, and with price reductions. In view of this scenario, Continuous Improvement (CI) initiatives could assist this sector to deal with its challenges and to survive in the global market. Two widely used and stand as the best CI initiatives are Lean and Six Sigma, that can be integrated in a hybrid approach, Lean Six Sigma, joining their strengths. To understand the relevance of adoption of these initiatives in the food industry context, this research firstly performed a systematic literature review, which found a low amount of papers published, late adoption of the initiatives in the sector, and their low use, indicating the sector lacks familiarity with the subject. In spite of that, some implementation cases showed the sector can benefit with their implementation. Several improvements in food industry’s performance can be obtained with their adoption, most of them related to cost reduction. Moreover, it was found that the main barriers to their use are strongly related to sector characteristics and managerial factors. Therefore, a survey was performed to better evaluate the potential for food industry to adopt Lean Six Sigma practices. First, a new multi-item measurement scales reflecting the multidimensional construct, Lean Six Sigma, in the food industry sector, was developed. A two-stage approach was used to ensure validity and reliability of the measurement items and scales. The scales were developed based on an initial set of 13 Lean and Six Sigma constructs and 73 items. They were purified and refined through four rounds of an item-sorting exercise and a prestest conducted using a questionnaire sent via web to fifty respondents (American Food and Beverage sector) from the SurveyMonkey Audience. Then, a large sample of 229 Brazilian and American food industries was used in order to confirm reliability and validity of Lean Six Sigma multi-item scales. The result was 11 constructs and 45 items to measure the adoption of Lean Six Sigma practices in the food sector. Then, a survey was conducted with 145 factories from Brazil and the United States. The findings showed a fragmented use of Lean Six Sigma practices; low adoption of practices related to pull, statistical process control and six sigma role structure; the effect of sector’s characteristics to a certain extent in the degree of adoption of Lean Six Sigma practices; and the positive effect of their adoption in the food industry’s performance, moderated by their level of experience. So, there is a great potential for the sector to adopt Lean Six Sigma practices; there are opportunities to increase the level of adoption of some practices low explored; expand the level of experience and the maturity of the sector in this field, and consequently, obtain better results with their adoption. |
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Costa, Luana Bonome MessageGodinho Filho, Moacirhttp://lattes.cnpq.br/6136685270563354http://lattes.cnpq.br/9911803539950651b7f3aed9-5b13-4004-895d-f9f13a8584712019-11-22T14:08:48Z2019-11-22T14:08:48Z2019-05-17COSTA, Luana Bonome Message. Lean & Six Sigma initiatives in the food industry. 2019. Tese (Doutorado em Engenharia de Produção) – Universidade Federal de São Carlos, São Carlos, 2019. Disponível em: https://repositorio.ufscar.br/handle/ufscar/12061.https://repositorio.ufscar.br/handle/ufscar/12061Food industry is an important sector that generates significant economic benefits. However, it is an industry that faces many challenges, due to the demanding market that requires a wide range of products, with short delivery times, frequent deliveries, and with price reductions. In view of this scenario, Continuous Improvement (CI) initiatives could assist this sector to deal with its challenges and to survive in the global market. Two widely used and stand as the best CI initiatives are Lean and Six Sigma, that can be integrated in a hybrid approach, Lean Six Sigma, joining their strengths. To understand the relevance of adoption of these initiatives in the food industry context, this research firstly performed a systematic literature review, which found a low amount of papers published, late adoption of the initiatives in the sector, and their low use, indicating the sector lacks familiarity with the subject. In spite of that, some implementation cases showed the sector can benefit with their implementation. Several improvements in food industry’s performance can be obtained with their adoption, most of them related to cost reduction. Moreover, it was found that the main barriers to their use are strongly related to sector characteristics and managerial factors. Therefore, a survey was performed to better evaluate the potential for food industry to adopt Lean Six Sigma practices. First, a new multi-item measurement scales reflecting the multidimensional construct, Lean Six Sigma, in the food industry sector, was developed. A two-stage approach was used to ensure validity and reliability of the measurement items and scales. The scales were developed based on an initial set of 13 Lean and Six Sigma constructs and 73 items. They were purified and refined through four rounds of an item-sorting exercise and a prestest conducted using a questionnaire sent via web to fifty respondents (American Food and Beverage sector) from the SurveyMonkey Audience. Then, a large sample of 229 Brazilian and American food industries was used in order to confirm reliability and validity of Lean Six Sigma multi-item scales. The result was 11 constructs and 45 items to measure the adoption of Lean Six Sigma practices in the food sector. Then, a survey was conducted with 145 factories from Brazil and the United States. The findings showed a fragmented use of Lean Six Sigma practices; low adoption of practices related to pull, statistical process control and six sigma role structure; the effect of sector’s characteristics to a certain extent in the degree of adoption of Lean Six Sigma practices; and the positive effect of their adoption in the food industry’s performance, moderated by their level of experience. So, there is a great potential for the sector to adopt Lean Six Sigma practices; there are opportunities to increase the level of adoption of some practices low explored; expand the level of experience and the maturity of the sector in this field, and consequently, obtain better results with their adoption.A indústria de alimentos é um importante setor, que gera benefícios econômicos significantes. Porém, ela é uma indústria que enfrenta muitos desafios, devido ao mercado exigente que requer uma ampla variedade de produtos, com tempos de entrega curtos e frequentes, e com reduções de preço. Frente a este cenário, as iniciativas de melhoria contínua poderiam auxiliar o setor a lidar com estes desafios e sobreviver no mercado global. Duas iniciativas amplamente utilizadas e destacadas como as melhores iniciativas de melhoria contínua são Lean e Seis Sigma, que podem ser integradas em uma abordagem híbrida, Lean Seis Sigma, unindo suas forças. Para entender a relevância da adoção dessas iniciativas no contexto da indústria de alimentos, esta pesquisa realizou primeiramente uma revisão sistemática da literatura, que encontrou uma baixa quantidade de artigos publicados, adoção tardia das iniciativas no setor e seu baixo uso, indicando a falta de familiaridade do setor com estas iniciativas. Apesar disso, alguns casos de implementação mostraram que o setor pode se beneficiar com a implementação dessas iniciativas. Várias melhorias no desempenho da indústria de alimentos podem ser obtidas, a maioria relacionada à redução de custos. Além disso, verificou-se que as principais barreiras ao seu uso estão fortemente relacionadas às características do setor e aos fatores gerenciais. Portanto, foi realizada uma pesquisa survey para melhor avaliar o potencial de adoção das práticas Lean Seis Sigma na indústria de alimentos. Primeiro, foi desenvolvida uma nova escala de medição, refletindo o construto multidimensional, Lean Seis Sigma, no setor da indústria de alimentos. Uma abordagem em duas etapas foi usada para garantir a validade e a confiabilidade dos itens e escalas de medição. A escala foi desenvolvida com base em um conjunto inicial de 13 construtos Lean e Seis Sigma e 73 itens. Eles foram purificados e refinados através de quatro rodadas de um exercício de classificação de itens (item-sorting) e um pré-teste realizado usando um questionário enviado via web a cinquenta entrevistados (setor de Alimentos e Bebidas Americanos). Em seguida, uma grande amostra de 229 indústrias alimentícias brasileiras e americanas foi usada para confirmar a confiabilidade e a validade da escala Lean Seis Sigma. O resultado foi 11 construtos e 45 itens para medir a adoção das práticas Lean Seis Sigma no setor de alimentos. Então, foi realizada uma pesquisa com 145 fábricas do Brasil e dos Estados Unidos. Os resultados mostraram um uso fragmentado das práticas Lean Seis Sigma; baixa adoção de práticas relacionadas à sistema puxado, controle estatístico de processos e estrutura Seis Sigma; o efeito das características do setor, em certa medida, no grau de adoção das práticas Lean Seis Sigma; e o efeito positivo de sua adoção no desempenho da indústria de alimentos, moderado pelo nível de experiência. Portanto, existe um grande potencial de adoção das práticas Lean Seis Sigma pelo setor; existem oportunidades para aumentar o nível de adoção de algumas práticas pouco exploradas; expandir o nível de experiência e a maturidade do setor nesse campo e, consequentemente, obter melhores resultados com sua adoção.Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)CAPES: código de financiamento - 001engUniversidade Federal de São CarlosCâmpus São CarlosPrograma de Pós-Graduação em Engenharia de Produção - PPGEPUFSCarAttribution-NonCommercial-NoDerivs 3.0 Brazilhttp://creativecommons.org/licenses/by-nc-nd/3.0/br/info:eu-repo/semantics/openAccessLean manufacturingSix SigmaLean Six SigmaFood industrySystematic literature reviewStructural equation modelingPLSLeanSurveySeis SigmaLean Seis SigmaIndústria de alimentosRevisão sistemática da literaturaModelagem de equações estruturaisENGENHARIAS::ENGENHARIA DE PRODUCAO::GERENCIA DE PRODUCAOLean & Six Sigma initiatives in the food industryIniciativas Lean & Seis Sigma na indústria de alimentosinfo:eu-repo/semantics/publishedVersioninfo:eu-repo/semantics/doctoralThesis6009e5a83c6-728c-4e41-946f-fd7a8431b1d6reponame:Repositório Institucional da UFSCARinstname:Universidade Federal de São Carlos (UFSCAR)instacron:UFSCARORIGINALTese_Luana.pdfTese_Luana.pdfTese de doutoradoapplication/pdf4714121https://repositorio.ufscar.br/bitstream/ufscar/12061/2/Tese_Luana.pdf9626b3c6678bbc5deb806ae1b977927aMD52Carta comprovante.pdfCarta comprovante.pdfapplication/pdf77495https://repositorio.ufscar.br/bitstream/ufscar/12061/4/Carta%20comprovante.pdfc94532c9352fa44a4e6a74ed060b1614MD54CC-LICENSElicense_rdflicense_rdfapplication/rdf+xml; charset=utf-8811https://repositorio.ufscar.br/bitstream/ufscar/12061/5/license_rdfe39d27027a6cc9cb039ad269a5db8e34MD55TEXTTese_Luana.pdf.txtTese_Luana.pdf.txtExtracted texttext/plain236197https://repositorio.ufscar.br/bitstream/ufscar/12061/6/Tese_Luana.pdf.txt4d4395d0fd36b42f6520dc10d40e6817MD56Carta comprovante.pdf.txtCarta comprovante.pdf.txtExtracted texttext/plain1332https://repositorio.ufscar.br/bitstream/ufscar/12061/8/Carta%20comprovante.pdf.txt94e573b825ad0b6fd74ed9e05ab73564MD58THUMBNAILTese_Luana.pdf.jpgTese_Luana.pdf.jpgIM Thumbnailimage/jpeg6114https://repositorio.ufscar.br/bitstream/ufscar/12061/7/Tese_Luana.pdf.jpgc18c11ad1d5b5303196b21d47f1b4935MD57Carta comprovante.pdf.jpgCarta comprovante.pdf.jpgIM Thumbnailimage/jpeg13339https://repositorio.ufscar.br/bitstream/ufscar/12061/9/Carta%20comprovante.pdf.jpg0359b40b16b7ca8285ca053d2a3cb395MD59ufscar/120612023-09-18 18:31:46.888oai:repositorio.ufscar.br:ufscar/12061Repositório InstitucionalPUBhttps://repositorio.ufscar.br/oai/requestopendoar:43222023-09-18T18:31:46Repositório Institucional da UFSCAR - Universidade Federal de São Carlos (UFSCAR)false |
dc.title.eng.fl_str_mv |
Lean & Six Sigma initiatives in the food industry |
dc.title.alternative.por.fl_str_mv |
Iniciativas Lean & Seis Sigma na indústria de alimentos |
title |
Lean & Six Sigma initiatives in the food industry |
spellingShingle |
Lean & Six Sigma initiatives in the food industry Costa, Luana Bonome Message Lean manufacturing Six Sigma Lean Six Sigma Food industry Systematic literature review Structural equation modeling PLS Lean Survey Seis Sigma Lean Seis Sigma Indústria de alimentos Revisão sistemática da literatura Modelagem de equações estruturais ENGENHARIAS::ENGENHARIA DE PRODUCAO::GERENCIA DE PRODUCAO |
title_short |
Lean & Six Sigma initiatives in the food industry |
title_full |
Lean & Six Sigma initiatives in the food industry |
title_fullStr |
Lean & Six Sigma initiatives in the food industry |
title_full_unstemmed |
Lean & Six Sigma initiatives in the food industry |
title_sort |
Lean & Six Sigma initiatives in the food industry |
author |
Costa, Luana Bonome Message |
author_facet |
Costa, Luana Bonome Message |
author_role |
author |
dc.contributor.authorlattes.por.fl_str_mv |
http://lattes.cnpq.br/9911803539950651 |
dc.contributor.author.fl_str_mv |
Costa, Luana Bonome Message |
dc.contributor.advisor1.fl_str_mv |
Godinho Filho, Moacir |
dc.contributor.advisor1Lattes.fl_str_mv |
http://lattes.cnpq.br/6136685270563354 |
dc.contributor.authorID.fl_str_mv |
b7f3aed9-5b13-4004-895d-f9f13a858471 |
contributor_str_mv |
Godinho Filho, Moacir |
dc.subject.eng.fl_str_mv |
Lean manufacturing Six Sigma Lean Six Sigma Food industry Systematic literature review Structural equation modeling PLS Lean Survey |
topic |
Lean manufacturing Six Sigma Lean Six Sigma Food industry Systematic literature review Structural equation modeling PLS Lean Survey Seis Sigma Lean Seis Sigma Indústria de alimentos Revisão sistemática da literatura Modelagem de equações estruturais ENGENHARIAS::ENGENHARIA DE PRODUCAO::GERENCIA DE PRODUCAO |
dc.subject.por.fl_str_mv |
Seis Sigma Lean Seis Sigma Indústria de alimentos Revisão sistemática da literatura Modelagem de equações estruturais |
dc.subject.cnpq.fl_str_mv |
ENGENHARIAS::ENGENHARIA DE PRODUCAO::GERENCIA DE PRODUCAO |
description |
Food industry is an important sector that generates significant economic benefits. However, it is an industry that faces many challenges, due to the demanding market that requires a wide range of products, with short delivery times, frequent deliveries, and with price reductions. In view of this scenario, Continuous Improvement (CI) initiatives could assist this sector to deal with its challenges and to survive in the global market. Two widely used and stand as the best CI initiatives are Lean and Six Sigma, that can be integrated in a hybrid approach, Lean Six Sigma, joining their strengths. To understand the relevance of adoption of these initiatives in the food industry context, this research firstly performed a systematic literature review, which found a low amount of papers published, late adoption of the initiatives in the sector, and their low use, indicating the sector lacks familiarity with the subject. In spite of that, some implementation cases showed the sector can benefit with their implementation. Several improvements in food industry’s performance can be obtained with their adoption, most of them related to cost reduction. Moreover, it was found that the main barriers to their use are strongly related to sector characteristics and managerial factors. Therefore, a survey was performed to better evaluate the potential for food industry to adopt Lean Six Sigma practices. First, a new multi-item measurement scales reflecting the multidimensional construct, Lean Six Sigma, in the food industry sector, was developed. A two-stage approach was used to ensure validity and reliability of the measurement items and scales. The scales were developed based on an initial set of 13 Lean and Six Sigma constructs and 73 items. They were purified and refined through four rounds of an item-sorting exercise and a prestest conducted using a questionnaire sent via web to fifty respondents (American Food and Beverage sector) from the SurveyMonkey Audience. Then, a large sample of 229 Brazilian and American food industries was used in order to confirm reliability and validity of Lean Six Sigma multi-item scales. The result was 11 constructs and 45 items to measure the adoption of Lean Six Sigma practices in the food sector. Then, a survey was conducted with 145 factories from Brazil and the United States. The findings showed a fragmented use of Lean Six Sigma practices; low adoption of practices related to pull, statistical process control and six sigma role structure; the effect of sector’s characteristics to a certain extent in the degree of adoption of Lean Six Sigma practices; and the positive effect of their adoption in the food industry’s performance, moderated by their level of experience. So, there is a great potential for the sector to adopt Lean Six Sigma practices; there are opportunities to increase the level of adoption of some practices low explored; expand the level of experience and the maturity of the sector in this field, and consequently, obtain better results with their adoption. |
publishDate |
2019 |
dc.date.accessioned.fl_str_mv |
2019-11-22T14:08:48Z |
dc.date.available.fl_str_mv |
2019-11-22T14:08:48Z |
dc.date.issued.fl_str_mv |
2019-05-17 |
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info:eu-repo/semantics/publishedVersion |
dc.type.driver.fl_str_mv |
info:eu-repo/semantics/doctoralThesis |
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doctoralThesis |
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publishedVersion |
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COSTA, Luana Bonome Message. Lean & Six Sigma initiatives in the food industry. 2019. Tese (Doutorado em Engenharia de Produção) – Universidade Federal de São Carlos, São Carlos, 2019. Disponível em: https://repositorio.ufscar.br/handle/ufscar/12061. |
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https://repositorio.ufscar.br/handle/ufscar/12061 |
identifier_str_mv |
COSTA, Luana Bonome Message. Lean & Six Sigma initiatives in the food industry. 2019. Tese (Doutorado em Engenharia de Produção) – Universidade Federal de São Carlos, São Carlos, 2019. Disponível em: https://repositorio.ufscar.br/handle/ufscar/12061. |
url |
https://repositorio.ufscar.br/handle/ufscar/12061 |
dc.language.iso.fl_str_mv |
eng |
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eng |
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600 |
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9e5a83c6-728c-4e41-946f-fd7a8431b1d6 |
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Attribution-NonCommercial-NoDerivs 3.0 Brazil http://creativecommons.org/licenses/by-nc-nd/3.0/br/ info:eu-repo/semantics/openAccess |
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Attribution-NonCommercial-NoDerivs 3.0 Brazil http://creativecommons.org/licenses/by-nc-nd/3.0/br/ |
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openAccess |
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Universidade Federal de São Carlos Câmpus São Carlos |
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Programa de Pós-Graduação em Engenharia de Produção - PPGEP |
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UFSCar |
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Universidade Federal de São Carlos Câmpus São Carlos |
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