The food industry is a key pillar of the global economy, where sustainability and effective resource management play a critical role in minimizing waste and maximizing efficiency. In food production, particularly in bakeries sustainability efforts center on reducing food, packaging, time and energy waste, lowering emissions, and improving overall economic performance. Company X, a leading food manufacturer in Saudi Arabia, operates a cake and pastry factory currently facing high waste levels in its bun production line. This project seeks to enhance sustainability by reducing waste to 1% through a comprehensive analysis of production processes, identification of key waste sources, and implementation of targeted, efficient solutions. By integrating sustainable practices into industrial bakery operations, the initiative aims to promote environmental responsibility while advancing operational excellence.

In the Define phase, SIPOC was used to map the process and identify plant-level waste. The Measure phase employed Pareto charts and statistical tools like Excel and Minitab to quantify losses. During the Analyze phase, fishbone diagrams, failure data, and machine reliability calculations uncovered root causes such as frequent breakdowns and process variation. In the Improve phase, proposed solutions were tested using Arena simulation software, and several improvements were implemented. Finally, the Control phase introduced a detailed monitoring and training plan to ensure sustained performance. As a result, food waste was reduced from 1.5% to 0.88%, OEE improved from 45% to 58.5%, and time loss decreased by 31.6%, overachieving factory targets, and supporting productivity and sustainability objectives.