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Output from the Irish Dairy Industry has grown rapidly since the abolition of quotas in 2015, with processors investing heavily in capacity expansion to deal with the extra milk volumes. Further capacity gains may be achieved by extending the processing season into the winter, a key enabler for which being the reduction of duration of the winter maintenance overhaul period. This paper aims to investigate if Lean Six Sigma tools and techniques can be used to enhance operational maintenance performance, thereby releasing additional processing capacity.

Combining the Six-Sigma Define, Measure, Analyse, Improve, Control (DMAIC) methodology and the structured approach of Turnaround Maintenance (TAM) widely used in process industries creates a novel hybrid model that promises substantial improvement in maintenance overhaul execution. This paper presents a case study applying the DMAIC/TAM model to Ireland’s largest dairy processing site to optimise the annual maintenance shutdown. The objective was to deliver a 30% reduction in the duration of the overhaul, enabling an extension of the processing season.

Application of the DMAIC/TAM hybrid resulted in process enhancements, employee engagement and a clear roadmap for the operations team. Project goals were delivered, and original objectives exceeded, resulting in €8.9m additional value to the business and a reduction of 36% in the duration of the overhaul.

The results demonstrate that the model provides a structure that promotes systematic working and a continuous improvement focus that can have substantial benefits for wider industry. Opportunities for further model refinement were identified and will enhance performance in subsequent overhauls.

To the best of the authors’ knowledge, this is the first time that the structure and tools of DMAIC and TAM have been combined into a hybrid methodology and applied in an Irish industrial setting.

Globally, consumer’s inclination towards functional foods had noticed due to their greater health consciousness coupled with enhanced health-care cost. The fact that probiotics could promote a healthier gut microbiome led projection of probiotic foods as functional foods and had emerged as an important dietary strategy for improved human health. It had established that ice cream was a better carrier for probiotics than fermented milked due to greater stability of probiotics in ice cream matrix. Global demand for ice cream boomed and probiotic ice cream could have been one of the most demanded functional foods. The purpose of this paper was to review the technological aspects and factors affecting probiotic viability and to standardize methodology to produce functional probiotic ice cream.

Attempt was made to search the literature (review and researched papers) to identify diverse factors affecting the probiotic viability and major technological challenge faced during formulation of probiotic ice cream. Keywords used for data searched included dairy-based functional foods, ice cream variants, probiotic ice cream, factors affecting probiotic viability and health benefits of probiotic ice cream.

Retention of probiotic viability at a level of >10⁶ cfu/ml is a prerequisite for functional probiotic ice creams. Functional probiotic ice cream could have been produced with the modification of basic mix and modulating technological parameters during processing and freezing. Functionality can be further enhanced with the inclusion of certain nutraceutical components such as prebiotics, antioxidant, phenolic compounds and dietary fibres. Based upon reviewed literature, suggested method for the manufacture of functional probiotic ice cream involved freezing of a probiotic ice cream mix obtained by blending 10% probiotic fermented milk with 90% non-fermented plain ice cream mix for higher probiotic viability. Probiotic ice cream with functional features, comparable with traditional ice cream in terms of technological and sensory properties could be produced and can crop up as a novel functional food.

Probiotic ice cream with functional features may attract food manufacturers to cater health-conscious consumers.