A Hybrid Framework For Integrating Lean Six Sigma And HACCP: Advancing Food Safety Compliance And Manufacturing Excellence

Syikilili, Lilian Mussa (2026) A Hybrid Framework For Integrating Lean Six Sigma And HACCP: Advancing Food Safety Compliance And Manufacturing Excellence. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

This study develops and analytically validates, within the selected case, a hybrid Lean Six Sigma (LSS)–Hazard Analysis and Critical Control Point (HACCP) framework for baseline risk–performance diagnosis in a mango pulp production line of a food manufacturing small and medium-sized enterprise (SME). This study applies a bounded Define–Measure–Analyze (DMA) approach to diagnose baseline food safety risk priorities and operational performance losses using company records and direct cycle time observations. HACCP provides food safety control logic; Failure Mode and Effects Analysis (FMEA) supports comparative risk prioritization; process capability index (Cpk) assesses the eligible continuous Critical Control Point (CCP) related variable; and Performance Loss Score (PLS) and Risk–Performance Coupling Matrix (RPCM) integrate risk priority with operational burden. The results showed that Step 15, Product Sterilization/Pasteurization, was the only confirmed CCP, with a CCP monitoring deviation rate of 10.71% and a weak baseline capability of Cpk = 0.31. The PLS results showed that the operational burden was highest at Step 1 Raw Mango Receiving and Inspection (0.517), Step 17 Aseptic Filling (0.515), Step 6 Trimming and Final Sorting (0.509), and Step 12 Pulp Storage (0.509), whereas the confirmed CCP, Step 15, had a moderate PLS value of 0.296. The RPCM identified Steps 15, 11, 17, 12, and 2 as the main baseline risk–performance priority points. Analytical validation was based on case-based application, traceable data handling, predefined scoring and normalization rules, and consistency between source records, analytical constructs, and the final outputs. The findings identify baseline priority points for future improvement and control without claiming the implementation of improvement outcomes.
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Penelitian ini mengembangkan dan memvalidasi secara analitis, dalam kasus terpilih, suatu kerangka hibrida Lean Six Sigma (LSS)–Hazard Analysis and Critical Control Point (HACCP) untuk diagnosis awal risiko–kinerja pada lini produksi pulp mangga di sebuah usaha kecil dan menengah (UKM) manufaktur pangan. Penelitian ini menerapkan pendekatan terbatas Define–Measure–Analyze (DMA) untuk mendiagnosis prioritas risiko keamanan pangan awal dan kerugian kinerja operasional menggunakan catatan perusahaan serta observasi langsung waktu siklus. HACCP menyediakan logika pengendalian keamanan pangan, Failure Mode and Effects Analysis (FMEA) mendukung prioritisasi risiko komparatif, process capability index (Cpk) menilai variabel kontinu yang layak dan terkait dengan Critical Control Point (CCP), sedangkan Performance Loss Score (PLS) dan Risk–Performance Coupling Matrix (RPCM) mengintegrasikan prioritas risiko dengan beban operasional. Hasil penelitian menunjukkan bahwa Langkah 15, Product Sterilization/Pasteurization, merupakan satu-satunya CCP yang terkonfirmasi, dengan tingkat deviasi pemantauan CCP sebesar 10,71% dan kapabilitas awal yang lemah, yaitu Cpk = 0,31. Hasil PLS menunjukkan bahwa beban operasional tertinggi terdapat pada Langkah 1 Penerimaan dan Inspeksi Mangga Mentah (0,517), Langkah 17 Pengisian Aseptik (0,515), Langkah 6 Pemangkasan dan Penyortiran Akhir (0,509), dan Langkah 12 Penyimpanan Pulp (0,509), sedangkan CCP terkonfirmasi, yaitu Langkah 15, memiliki nilai PLS sedang sebesar 0,296. RPCM mengidentifikasi Langkah 15, 11, 17, 12, dan 2 sebagai titik prioritas awal utama pada hubungan risiko–kinerja. Validasi analitis didasarkan pada penerapan berbasis kasus, penanganan data yang tertelusur, aturan penilaian dan normalisasi yang telah ditetapkan sebelumnya, serta konsistensi antara catatan sumber, konstruk analitis, dan keluaran akhir. Temuan penelitian ini mengidentifikasi titik-titik prioritas awal untuk perbaikan dan pengendalian di masa mendatang tanpa mengklaim adanya hasil perbaikan yang telah diimplementasikan.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Lean Six Sigma; HACCP; FMEA; Performance Loss Score; Risk–Performance Coupling Matrix; keamanan pangan; kapabilitas proses; kinerja operasional
Subjects:	T Technology > TS Manufactures > TS155 Production control. Production planning. Production management
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26101-(S2) Master Thesis
Depositing User:	Lilian Mussa Syikilili
Date Deposited:	03 Aug 2026 07:46
Last Modified:	04 Aug 2026 06:46
URI:	http://repository.its.ac.id/id/eprint/142247

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