This dissertation presents the integration of sustainability elements, Lean and Six Sigma approaches to drive a continuous improvement project as a case study in food processing industry. Continuous Improvements (CI) have been constantly implemented across the world using Lean and Six Sigma approaches with environmental consideration. However social sustainability element shows insufficient development, a fact which is supported by literature review consisting of more than 40 papers. The case study is planned to address the gap and validate the improvements of process and sustainability elements through solution proposal while minimizing wastes in production. Black line defect characteristics are analyzed using descriptive and visual analysis to understand current condition. The goal is to reduce defects by at least 30% to 50%. Lean Six Sigma approach have been used to identify root causes and mechanisms contributing black line defect. LSSS Model have been constructed to guide case study methods towards achieving good process performance and sustainability. Solution designs have been fabricated and tested to evaluate effectiveness in solving the black line issue. Results of after improvement shows 71.4% reduction in black line defect and improved worker satisfaction at workplace. Goal for case study project have been achieved. Since the Sigma level is still at 4, further improvements can be made in the future to achieve better sigma level.
