Implementación de la Metodología DMAIC en el proceso productivo de chocolate amargo en la Asociación de Productores de Cacao de Arosemena Tola Tsatsayaku

Abstract

The objective of this degree research was to implement the DMAIC methodology in the production process of bitter chocolate in Asociación de Productores de cacao de Arosemena Tola TSATSAYAKU. It began with the definition stage, where, with the project charter, it was established that the existence of lumps within the 250 g bitter chocolate bars was the main problem, then in the measurement stage, the bitter chocolate particle size data was recorded, followed by the analysis stage where 5 tools were implemented: 5 whys, Ishikawa diagram, cause and effect matrix, Pareto diagram and analysis of variance, in order to determine the most influential factors of the problem. Later, in the improvement stage, it was established that the best treatment to produce a product with less presence of lumps is: to use 24 kg of nibs (crushed cocoa beans without shells), with new suction hoses and using the Kimberly processing method. Finally, in the control phase, data were recorded on the particle size of the bitter chocolate, where control charts showed that the process was stable. As a result, a 46% reduction of lumps was obtained, and at the same time most of the bitter chocolate particle size complied with the limits established by the association. It was concluded that there are three main factors to reduce the presence of lumps: lack of operator skill, damaged suction hoses and cocoa husks. For the elaboration of a quality product, the results achieved in the analysis phase should be taken into account, as well as the control plan carried out to maintain the implemented improvement over time.