Manufacturing · MFG-07
Strengthening Quality and Production Control in Food-Grade Plastic Packaging
Business challenge
The manufacturer of food-grade, virgin plastic packaging solutions was experiencing significant product-quality issues, including customer complaints regarding foreign materials being found in containers. The company also carried excess finished-goods inventory and required stronger systems to improve capacity utilisation, reduce production wastage, control defects, and strengthen operational discipline.
What we did
Reviewed the production and quality-control processes to identify potential sources of defects, contamination, wastage, and process variation.
Developed SOPs and introduced a structured Non-Conformance Report process for recording, investigating, and closing quality deviations.
Trained the team in Root Cause Analysis and Corrective and Preventive Action and provided standard templates for documenting causes, actions, responsibilities, and closure.
Introduced scrap weighing and wastage-percentage measurement, along with production data capture for efficiency, utilisation, downtime, yield, and changeover time.
Strengthened inventory reliability through physical stock audits and standardised product nomenclature, improving consistency in production and stock records.
Systematised machine and mould utilisation through machine-to-mould mapping, creating a foundation for lower wastage and more effective production planning.
