Quality Improvement

REDUCTION OF DEFECT RATES USING DESIGN OF EXPERIMENTS

Background and initial SITUATION

An extravagant new packaging style was selected for a new product. The new product packaging style turns out to be problematic in terms of production

Problem: 20% of the packages show cracks or closure problems
Target: Reduction of defect rate to <2%; benefit: > 5 Mill. EUR

VERIFIED ROOT CAUSES 

  • Style of packaging not ideal for the chosen material
  • Suboptimal production settings selected for this application
  • Existing systems for material testing and specifications unsuitable for this material application

IMPLEMENTED SOLUTIONS

  • New, much tighter and customized production settings for supplier and producer
  • Optimization of test systems and specifications
  • Optimization of packaging machines in the second generation
  • Planning optimization of product layout

Added value for companY and customerS

  • Reduction of defect expenses around approx. 5 Mill. EUR
  • Introduction of a new and robust test procedure for the material
  • Improved customer retention and integration of supply chain through the joint project