The commercialization of the açaí fruit has increased considerably since the 1990s, boosting demand and the price of the fruit as well as attracting new investments in the açaí pulp processing industries to the northeastern region of the State of Pará. Therefore, this study aims to use the principles and methods of Lean Six Sigma to propose improvements to the açaí pulp processing process. These improvements aim to reduce machine downtime to provide the company with greater profitability and the development of continuous flow. First, a literature study was carried out to understand the methodologies of Lean Manufacturing and Six Sigma and how they complement each other. Then we used the Six Sigma method, DMAIC, with the Define, Measure, and Analyze phases. In this phase, the main reasons were identified and the percentage of stoppages that each one represents on the line, such as lack of product in the process area (33.75%), lack of production order (23.91%), change of laminates and coils (12.7%), cleaning before production (7.49%), and mechanical breakdown or failure (7.35%), which together account for 85.2% of the line's total stoppages. Therefore, an action plan was proposed for each reason identified to reduce or eliminate it. The main limitations of the research were the lack of a qualified team and a centralized organizational culture that would allow faster data analysis. Some of the main practical implications include statistical methods for decision-making in the açaí agro-industry, a sector that has sought to professionalize its management and improve the supply of its products.
Keywords: Açaí industry; Lean Six Sigma application; Downtime reduction; Flow.