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Optimizing Sack Utilization in a Sorting Center Through Six Sigma Approach
Subject area: Science,Engineering and Technology · Area of research: Six Sigma
Abstract
This study focuses on optimizing sack utilization in a parcel sorting center by applying the Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) methodology. The current practice of using only new sacks for daily operations has resulted in increased operational costs and environmental waste. Through process mapping, root cause analysis, and the implementation of standardized procedures for sack issuance, sorting, and reuse, the study significantly improved the reusable sack rate from 21.75% to 77.47%. Key initiatives included the development of a sack calculator based on daily parcel volume, sack sorting criteria (Sack Matrix), and standardization of request and issuance processes. These improvements not only enhanced operational efficiency but also resulted in substantial cost savings of approximately PHP 7 million (USD 127,000). The research highlights the synergy of Lean Six Sigma principles and green logistics practices in driving both cost-effectiveness and sustainability in logistics operations.
Keywords
Six Sigma, DMAIC, logistics, operational cost reduction, green logistics, lean methodology, sorting center, sustainability, process improvement
References
[1] Ahmad A., & Khan A., (2021)., “The combined implementation of Green, Lean and Six Sigma approaches for achieving environmental sustainability - A Review”., Volume 1224 (2022) 012004, Page 2-3., doi:10.1088/1757-899X/1224/1/012004.
[2] Gultom G. & Wibisono E., 2018., “A framework for the impact of lean six sigma on supply chain performance in manufacturing”., Volume. 528(2019) 012089, Page 2-3., doi:10.1088/1757-899X/528/1/012089.
[3] Logistic Green Label. (2025, January 20). Waste in Logistics: A challenge and an Opportunity for Sustainability. Retrieved from https://www.logisticgreenlabel.org/en/green-logistic/waste-in-logistics-a-challenge-and-an-opportunity-for-sustainability
[4] Maheshwari A., April 7, 2024., “Green Logistics in the Philippines: Paving the Way for a Sustainable Future”., portcalls.com., Retrieved from https://portcalls.com/green-logistics-in-the-philippines-paving-the-way-for-a-sustainable-future/
[5] Padua, B. D. G., Florencondia, N. T., & Villar, M. J. (2025). Employer perspectives on project management effectiveness: An engineering management analysis of BSME 2019 graduates' contributions to engineering projects. International Journal of Progressive Research in Science and Engineering, 6(1). Retrieved from ResearchGate
[6] Uyar, R.A., & Bilgin, G. (2011). Application of Six Sigma methodology in reducing logistics cost: A case study in a distribution company. International Journal of Lean Six Sigma, 2(2), 139-155. https://doi.org/10.1108/20401461111189436
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How to cite this paper
@article{1708360,
author = {Michael Angelo L. Cadag, Noel T. Florencondia, Christopher M. Ladignon},
title = {Optimizing Sack Utilization in a Sorting Center Through Six Sigma Approach},
journal = {Iconic Research And Engineering Journals},
year = {2025},
volume = {8},
number = {11},
pages = {356-361},
issn = {2456-8880},
url = {https://www.irejournals.com/formatedpaper/1708360.pdf},
abstract = {This study focuses on optimizing sack utilization in a parcel sorting center by applying the Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) methodology. The current practice of using only new sacks for daily operations has resulted in increased operational costs and environmental waste. Through process mapping, root cause analysis, and the implementation of standardized procedures for sack issuance, sorting, and reuse, the study significantly improved the reusable sack rate from 21.75% to 77.47%. Key initiatives included the development of a sack calculator based on daily parcel volume, sack sorting criteria (Sack Matrix), and standardization of request and issuance processes. These improvements not only enhanced operational efficiency but also resulted in substantial cost savings of approximately PHP 7 million (USD 127,000). The research highlights the synergy of Lean Six Sigma principles and green logistics practices in driving both cost-effectiveness and sustainability in logistics operations.},
keywords = {Six Sigma, DMAIC, logistics, operational cost reduction, green logistics, lean methodology, sorting center, sustainability, process improvement},
month = {May},
}