**Abstract**

The aim of this study objective is to develop an integrated constant quality improvement model so as to minimize unwanted biscuit processing industry wastes. The method used was lean- six- sigma elements to define measure and improve unwanted process company wastes. In other word, Baldrige with six-sigma were created to define, measure and improve management perspectives. The tasks were integrated using both quantitative and qualitative analyzing tools implementing mixed strategies. The result was improved by using FMEA analysis was carried out at each stage of the existing process used to determine the failure of the process and to analyses and improve the production quality. The SPSS software was also used. In the finding section, the correlation and regression analysis has shown that there is strong relationship between each variance. There are different wastes that identified in six sigma (DMAIC) on NAS food Plc as a result; the value of waste ratio indicated is 36.7%. This show non-lean of the food industry is practiced. The defect of the company also calculated and defect per million are 67,308. This shows that the biscuit production has a production capability with a failure of 67,308 every 1000,000 productions it high failure rate. The contribution of the paper has indicated that there are limited studies were conducted so far to implement waste minimization tools like six-sigma, lean and MBNQA framework approach integration for food processing industry.

**Keywords:** waste, lean, DAMIC, CQI, MBNQA

### **1. Introduction**

Companies are more competitive in current globalization and every detail is important for the business that wants to improve its competiveness. Since it is not a surprise, the best continuous improvement strategies that could be developed for manufacturing industries provide to improve efficiency and effectiveness of whole systems. Though, automating production and improving process efficiency are two major objectives of the food industry worldwide. Since, implementing advanced continues an improvement strategy in the modern manufacturing provides to

improve the performance of the process, reduce waste and ensure on time delivery of the sectors [1]. Because of the continuous improvement is a management philosophy that approaches to tackle the challenge of product and increase process improvement [2]. Thus, from numerous tools firms were invested to implement lean, six-sigma, TQM and JIT strategies in their business process so as to enhance performance and compete at global levels [3]. Though the lean principle provides to identifying and eliminating non value add (wastes) through continuous improvement tools, flowing the product at the pull of the customer in pursuit of perfection [4]. Since due to comprise on quality development, process focus, continuous improvement and value stream management and worker empowerment future several companies invest in the implementation lean principles [3]. While six sigma is a really effective tool for systematically attacking the highest priority production and support functional problems within an organization [4]. Hence, six sigma is statistical measure of defect rate within a system and the practice requires the knowledge of basic and advanced statistical tools so as to reduce defects and variations within a work process in firm. But the main limitations are six sigma not effective for every problem reduction in the firms [5]. Baldrige national quality award (MBNQA) for helping excellence ever, improving value to marketplace success, improvement of overall organizational effectiveness and capabilities, organizational and personal learning. Though from the above observe that a single improvement tools lacks to coherence to tackle the whole problems of the manufacturing firms. Single tools have good potential to tackle specific problems. Even though, an integrated continuous improvement strategies and methods have great power to improve the performance and the competitiveness of the firms [6]. As long as fewer studies were investigate to implements the integration of lean with six sigma, lean with TQM strategies in the firm so as to improve the performance and global Competitiveness [4]. Therefore integrating three or more continuous improvement strategies provides to enhance, quality of products, optimum product cost, timely delivery of products,the flexibility of their internal business process, reduction of wastes and customer satisfactions [3]. Thus, this study aims to develop an integrated frame work from lean, six sigma and the Malcolm Baldrige Criteria so as to improve the production performance, reduce waste and improve competitiveness of NAS Foods Plc.
