Enhancing Supplier Capability Through Waste Minimization: A Quality Matrix Perspective

Abstract

In the packaging sector, even minor deviations in product specifications can lead to increased waste, operational inefficiencies, and compromised product quality. This research focuses on addressing critical manufacturing challenges faced by Company A in maintaining ovality standards for polymer cans exceeding the acceptable threshold (≤3%) or 1.2mm which is pivotal for packaging integrity. Using a combination of advanced tools like the Hoshin Kanri X-Matrix methodology for strategic alignment and integrates tools like root cause analysis (Ishikawa), Pareto analysis, and experimental validation to identify key factors influencing deformation, including load, packaging, and temperature variations. The samples were analyzed, controlled experiments and correlation analyses confirmed that load management significantly reduces deformation, while temperature has minimal impact. By implementing improved packaging designs, including the use of 5-ply separators, floor rejections were reduced from 5% to 1.1%, reduced man-hours by 50%, yielding financial savings of 8.76 MN PKR annually and enhancing operational efficiency.

Keywords: Continuous improvement, Defect reduction, Lean manufacturing, Load management, Packaging quality, Supplier capability, Waste minimization.