Abstract
traditional processing methods prevalent in Imo State's agro-processing hubs, limiting its export
potential. This study investigates the application of Six Sigma methodologies, including the DefineMeasure-Analyze-Improve-Control (DMAIC) framework and statistical process control (SPC), to
reduce defects and enhance consistency in garri production. Employing a mixed-methods case
study design, data were collected from five small scale factories through process observations,
microbial analyses, and interviews with 25 personnel. Baseline assessments revealed a 28.4%
defect rate (sigma level 2.3), primarily from inconsistent fermentation, poor hygiene, and variable
roasting. Root cause analysis identified key contributors, leading to pilot interventions such as
standardized protocols and mechanization, which reduced defects to 8.2% (sigma level 3.8),
lowered costs by 15%, and improved yields to 82%. These enhancements align garri with
international standards, fostering export opportunities in a $3.65 billion global market. The
findings highlight Six Sigma's efficacy in optimizing agro-industries, recommending policy
support for training and mechanization to promote sustainable development in Nigeria's rural
economies.