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All Journal IJIES (International Journal of Innovation in Enterprise System)
Muhammad Hudzaly Hatala
Institut Teknologi Kalimantan
Control & Systems Engineering Engineering

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Diagnosing Defects and Waste in an SME Bakery Using Lean Six Sigma Anggun Nindy Fatliana; Muhammad Hudzaly Hatala; Nuraini Rahmad; Vira Aulia
IJIES (International Journal of Innovation in Enterprise System) Vol 10 No 2 (2026): International Journal of Innovation in Enterprise System - Article in Press
Publisher : Telkom University

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.25124/ijies.v10i02.10514

Abstract

Product-quality problems create material losses and operational inefficiencies for resource-constrained food SMEs. This study diagnoses product defects and production waste at Ronalee Bakery, an Indonesian bakery SME, using selected Lean Six Sigma tools. Aggregate production and defective unit records from January to March 2024 were analyzed together with process observations and operational accounts. The DMAIC framework was used to organize the diagnostic process: the Define, Measure, and Analyze stages were applied to identify problems and their potential causes, whereas the Improve and Control stages were limited to proposed actions. Of the 101,421 units produced, 3,367 were recorded as defective, corresponding to an aggregate defective-product rate of 3.32%, which exceeded the company’s target of 2%. The assessment identified burnt bread, under-risen bread, torn or hollow texture, filling leakage, and non-standard weight, along with several relevant waste categories, including waiting, overproduction, overprocessing, inventory, and transportation. Potential causes were associated with operator capability, raw material and formulation consistency, oven condition, production planning, and facility layout. Proposed actions include standardized operating procedures, operator training, preventive maintenance, demand-based production planning, and layout adjustments. These findings provide a structured diagnostic basis for the future implementation and evaluation of quality-improvement actions in resource constrained bakery SMEs.
Co-Authors Anggun Nindy Fatliana Nuraini Rahmad Vira Aulia