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By Kanchan Ray, Chaitali Sengupta
60 mins
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success story

Streamlining precision-filling and enhancing packaging design

Reducing overfill and eliminating wastage for a leader in the global beauty and fragrance industry.
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business need

As a global leader, the client wanted to adopt processes in line with the competitive market. The client realized its bottle filling process generated more waste than expected. This was partly due to some lines overfilling containers to ensure aesthetic results, which led to higher expenses on supplies. Considering the price of some of the fill liquids, this was a significant opportunity to reduce overfill and save money.

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solution
Nagarro’s experts partner with the client to leverage the cloud-based shop floor quality and analytics platform and ensure the most effective deployment of the solution. The SPC Fill Height Project was incrementally implemented on 12 fragrance lines. The company set target amounts for every SKU (2,600 parts), control limits for each product and line combination (filling variation), and specification limits (min and max fill height levels). The process also included training for more than 100 users, from line operators and quality inspectors to managers and directors.
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outcome
This implementation has resulted in significant financial and resource savings. An initial investment of $47,000 and careful execution ensured that the projects reduced variation, increased accuracy of set points, validated process capability, and reduced overfilling, all at once. Packaging design engineers also reviewed the bottle designs that ensured ideal liquid fill amounts without compromising the overhead space. The drastic drop in overfill saved over $270,000 in the first year and brought an ROI of more than 500%.

By incorporating this solution into our plant floor quality efforts, we realized benefits across all parts of the value chain—from quality professionals that experience unprecedented database accuracy, to executives seeing financial savings.

- VP, Operations