Implementation of Kaizen Approach and Six Sigma Methodology to Improve Organic Eggs Productivity

The application of Six Sigma methodology, through the DMAIC approach, allowed to identify opportunities for improvement in the production process of organic eggs. It was determined that one of the processes with the greatest variability was egg collection and cleaning. Therefore, the process was redesigned improving the collection process and the egg cleaning to maintain the quality and increase egg production. In the Measurement phase, a statistical analysis of processes was carried out, obtaining as a result process capacity (Cp) of 0.92, upper process capacity (Cpks) of 0.55, and 1.29 for lower process capacity (Cpki). These results determined that the process presents a high variability. The DMAIC approach stabilized the process by increasing the values of the upper control limit with 610 eggs and the lower control limit with 178 eggs per day, thus obtaining values of 1.02, 1.01, and 1.00 for Cp, Cpks, and Cpki, respectively, which indicate stability in the process. Then, fulfilling the objective of the Six Sigma methodology is to reduce the variability of the production process. An improved distribution of the shed was carried out, increasing 10 nests and 10 feeders to do the egg collection faster and more efficiently. The new distribution of the shed improved significantly the organic egg production process and reduced the mortality rates of the hens. It is necessary to change the mentality of the workers for the implementation of the methodology. Quality is a key indicator to position the business in the Ecuadorian organic egg market.