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ExpressPoint recently completed two Lean Six Sigma projects focused on quality improvement and cost reduction for the packaging products used to ship customer finished goods. Engineer Roberto Rodriguez led a project in our Juarez, Mexico plant which resulted in improved quality results through the redesign of three high-volume packages. Meanwhile, at our Golden Valley location, Engineer Kevin Lange led a separate project focused on reducing the variety of packaging used for a specific customer program.
The Juarez project, titled "Six Pack" (Six Sigma Packaging), reviewed the top six packaging styles used in that plant. After analysis, three of these packages were identified as opportunities for improvement in quality. Redesigns included changing the peanut bag packaging to polyurethane foam end caps, foam with removable pieces allowing flexibility for use on more than one product, and redesigned foam inserts with special cutouts to provide increased protection for printer trays and fragile flippers that "stick out." The new designs were sent through rigorous drop-testing prior to use and product returns were tracked for months to insure quality. In addition to being of higher quality, the new designs were also more cost effective and allowed for some recycling, decreasing overall costs by an estimated 15%.
The Golden Valley project was focused on reducing the variety of packaging parts used for a unique program, thus concentrating volumes among fewer products. This allowed us to negotiate lower prices on these products as well as improve inventory turnover and reduce the risk of excess inventory. The project team evaluated all 70 packaging products, used for this specific program, to determine suitability for use on multiple parts. Significant drop-testing was conducted, customer approval obtained and ultimately 13 package designs were eliminated from use, an 18.5% reduction. The team is continuing to look at other customer programs for similar consolidation opportunities.
As always, ExpressPoint continues to look for opportunities to utilize our Lean Six Sigma tools to improve quality and delivery while reducing costs for our customers.