Product Quality
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Product Quality
Implementation Engineers executes product quality enhancements for our clients, ranging from broad Quality Management System (QMS) implementation, to focused defect reduction projects. Our team specializes in implementing tailored strategies and proven methods to enhance product quality, ensuring that our clients meet and exceed customer requirements and expectations. In Six Sigma quality projects we often use a structured and proven DMAIC (Define – Measure – Analyze – Improve – Control) approach to address defects and improve quality. Alternatively, we may engage upstream in the product engineering and design process using a Design for Six Sigma (DFSS) approach. Regardless of the specific problem solving methodology deployed, we work closely with organizations to identify key areas for improvement and implement quality control measures to enhance overall product performance.
31% improvement in dry scrap rate
49% improvement in wet scrap rate
$2.3M project benefits
IX® in Action
Our client, a private equity firm that owns a pet food manufacturing business, faced challenges in meeting output and quality targets while also generating a significant amount of dry and wet scrap. Seeking to enhance operations and product quality, our client collaborated with Implementation Engineers. Leveraging the Design of Experiments (DOE) methodology, Implementation Engineers implemented innovative solutions to address product quality issues. DOE, a robust statistical tool, enabled us to systematically design, conduct, and analyze experiments to optimize product quality and performance. Through numerous quality defect reduction projects and the implementation of various improvements, Implementation Engineers successfully reduced scrap levels and enhanced overall operational efficiency for our client's pet food manufacturing facility. Activities during IX® included:
- Conducted a Moisture Variability Design of Experiments on the spreader arm
- Conducted a Moisture Variability Design of Experiments on the dryer
- Implemented quality defect reduction projects
- Installed a vacuum line hose to convert product left in the hoppers to rework instead of dried scrap
- Implemented bag deflators on packaging lines to remove excess air in the bags to reduce the number of popped bags
