The Mitigation of Raw Material Waste in the Production of Coffee by Applying Lean Six Sigma

December 2, 2025

This thesis investigates the application of Lean Six Sigma methodology to reduce raw material waste in coffee processing factories. The study begins by analysing the food and coffee industries, highlighting their unique challenges, competitive pressures, and value chain dynamics. The current production processes are examined in detail, from the transport and cleaning of green coffee to roasting, storage, and packaging, identifying key inefficiencies and opportunities for improvement. A literature review is presented on Lean, Six Sigma, and Lean Six Sigma, covering their history, principles, and successful applications in food manufacturing. The research methodology follows the DMAIC framework—Define, Measure, Analyse, Improve, and Control—applied to the specific context of coffee processing. Data collection, value stream mapping, root cause analysis, and pilot testing of improvement strategies are detailed. Results demonstrate significant reductions in waste and improvements in process efficiency, with estimates of the annual benefit derived from these interventions. The study concludes with practical recommendations for sustaining gains and outlines potential directions for future research.

Authors in the community:

• 

  R

  Rodrigo Miguel Correia Gomes

  ist196311

Supervisors of this institution:

• 

  D

  Daniel Rebelo dos Santos

  ist167904

other-engineering-and-technologies - Other engineering and technologies

eng - English

Instituto Superior Técnico