FJC Packaging Consultants

The Challenge

A flexible pouch converter contacted us after their quality defect rate had dramatically increased from under 0.5% to over 5% in just one year. They needed fast identification of the root causes and practical solutions to restore their previous high-quality standards.

 

Our Approach

We needed to learn about our clients converting processes, defect history, QC system including incoming, in-process, and final QC inspections. We also wanted to understand the training programs for QC and converting staff.

 

Our Solution:

After analyzing two years of defect records and observing the client's manufacturing & QC processes, several critical issues became clear:

• The sharp rise in defects was concentrated in one specific pouch style.

• Quality testing was being performed inconsistently — often by machine operators instead of trained QC staff. Training was also not consistently applied to all employees in the manufacturing process.

• Tests were frequently conducted at the end of production runs rather than during them, allowing defective product to be boxed and sometimes shipped before issues were caught.

 

We worked with the client to strengthen their Quality Management System (QMS) with the following targeted improvements:

• Developed and implemented a comprehensive QCIP (Quality Control Inspection Plan) that clearly listed the required tests, frequency of testing, test results, who performed the test, the exact time of testing, and the specific box the sample came from.

• Formal line clearance procedures for shift changes and breaks.

• Introduction of portable QC stations equipped with necessary testing tools, allowing QC staff to move efficiently between machines.

• Increased QC staffing so trained quality personnel could take ownership of testing, freeing operators to focus on production. We also removed converting staff from the testing process. 

• Regular internal audits by QC management to ensure procedures were being followed consistently.

 

The Outcome

Within months of implementing these changes, the converter’s quality defect rate began dropping steadily. The improvements restored process control, reduced waste, and rebuilt confidence in their product quality.

 

This project demonstrates how targeted quality system enhancements — combined with practical changes in staffing and workflow — can deliver rapid and sustainable improvements in manufacturing performance.

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Project Timeline 6 months