A Systematic Review of Lean Six Sigma and HACCP Integration in the Food Industry: Toward Manufacturing Excellence and Compliance

Abstract

Background: This study analysed the integration of Lean Six Sigma (LSS) and Hazard Analysis and Critical Control Points (HACCP) in food manufacturing, with particular attention to Small and Medium-Sized Enterprises (SMEs).

Methods: A systematic literature review was conducted following PRISMA 2020 guidelines and the PICOS framework. Articles were retrieved exclusively from the Scopus database. The search was conducted in July 2025 and covered publications from 2015 to 2025. A total of 770 records were identified, and after duplicate removal and eligibility screening, 65 peer-reviewed studies were included for qualitative synthesis. Screening and data extraction were performed manually using Excel.

Results: The review showed that most of the analysed studies reported positive impacts of LSS–HACCP implementation across sectors such as packaging, dairy, meat, seafood, and confectionery. Lean tools, including visual management, Value Stream Mapping (VSM), Total Productive Maintenance (TPM), and 5S, were frequently applied to improve process standardisation, reduce waste, and strengthen documentation practices in SMEs. Six Sigma tools, particularly Define, Measure, Analyze, Improve, Control (DMAIC) and Failure Mode and Effects Analysis (FMEA), were reported to enhance defect control and support structured risk prioritisation in quality-critical processes.

Conclusions: Despite the documented benefits of integration, several obstacles persist, including limited access to structured guidance, inconsistent documentation practices, and a lack of technical expertise. This analysis highlights the necessity for flexible, hybrid models that integrate HACCP and LSS to support manufacturing excellence and maintainable food safety procedures. Validating such models in SME contexts should therefore be a priority for future research.