Industrial Food Process Improvement by Waste Minimization in Pasta Packaging Using DMAIC Methodology

The food industry faces a growing challenge concerning improving operational efficiency and reducing waste to maintain competitiveness and meet sustainability purposes.This study explores the application of the Define-Measure-Analyze-Improve-Control (DMAIC) methodology as a critical part of the Lean Six Sigma (LSS) framework, as a structured, data-driven approach to identifying and eliminating raw material waste in the packaging phase of pasta production.The primary objective was to investigate the root causes of waste and implement targeted improvements to enhance industrial process performance in pasta packaging.Real production data from a pasta manufacturing facility were collected and analyzed, focusing on the packaging stage where significant losses had been observed.The DMAIC cycle guided the project through problem definition, data measurement, root cause analysis, process improvement, and long-term control strategies.The analysis identified key operational issues, including overfilling, equipment settings, and inadequate material handling.Equipment reconfiguration, staff training, and standardization of procedures were implemented, resulting in measurable reductions in raw material losses and improved packaging accuracy.An economic evaluation demonstrated that these improvements were effective from an operational standpoint and also generated a positive return on investment.The findings confirm that the DMAIC methodology provides a scalable and repeatable model for reducing waste and improving efficiency in food production environments.This research emphasizes the importance of structured problem-solving approaches in achieving ecologically and socially sustainable, as well as economically viable, process improvements in the food industry.