REVIEW OF INTERNATIONAL GEOGRAPHICAL EDUCATION

ISSN: 2146-0353 ● © RIGEO ● 11(10), SPRING, 2021

www.rigeo.org Research Article

Defective Reduction in Printing Process of

Flexible Packaging
Using Six Sigma Approach: A Case Study of
Thai Manufacturing
Walailak Atthirawong1, Wariya Panprung2, Amporn Sangmanee3, Woranat Sangmanee4
1Department of Applied Statistics, School of Science, King Mongkut’s Institute of Technology
Ladkrabang, Bangkok, Thailand
2Management Science Department, Phranakhon Rajabhat University, Bangkok, Thailand,
noiwari@gmail.com
3Assistant Governor, Internal Audit Group, Bank of Thailand, Thailand, Ampors@bot.or.th
4KMITL Business School, King Mongkut’s Institute of Technology Ladkrabang, Bangkok, Thailand,
woranat.sa@kmitl.ac.th

Corresponding author: Email: walailaknoi@gmail.com

Abstract
The purpose of this study were 1) to deploy six sigma approach to reduce the defective in off
registration and smearing color in printing process of flexible packaging 2) to investigate root cause
and determine corrective action plan of off registration and smearing color problems. Six sigma
approach consists of 5 steps, i.e. Define Phase, Measure Phase, Analyze Phase, Improve Phase and
Control Phase. In this study, off registration and smearing color problems in printing process from a
case company were chosen, from various defects and numbers of customer complaint. The first phase
aimed to determine the repeatability and reproducibility of attribute Gauge R&R study. Using the
process map analyzed the root cause and selected the key factor from Cause and Effect Matrix, Then,
the key factor were analyzed their defect characteristic and effect from FMEA (Failure Mode Effect
Analysis). After that, the actual root cause was analyzed, corrective action and preventive action plan
were established in order to decrease defect and prevent repeatable problems. After applying six
sigma approach from July’2020 to February’2021, it was found that defects in printing process could
be reduced up to 50% (from 14.3% to 7.2%). When comparing with level, it can be improved
from 2.6 to 3.0 . The results also revealed that off registration defective can be reduced from
5.1% to 2.6%, and smearing color defective could be reduced from 3.7% to 1.4%. Therefore, if
management teams control the process constantly, waste would be reduced continuously.

Keywords
defective reduction, six sigma, printing process, flexible packaging.
© RIGEO ● Review of International Geographical Education 11(10), SPRING, 2021

Introduction
Nowadays, every kinds of industry have face the severe competition both internal and
external countries. Packaging manufacturing industry involves with other manufacturing,
commerce, agriculture and also service sectors, which are used packaging to be a part of
their promotion and sale. In order to manage modern market, not only price, place,
promotion and product, packaging is the material to advertise and persuade consumer to
purchase goods with the main qualification to protect the freshness, attraction and
sanitation of product. Including with the brand of product is on the packaging material,
another method to advertise the quality of company’s brand at the selling shelf.
Furthermore, changing of economical structure from producing and exporting agriculture
product to be an industrial product more, it causes packaging industry to magnify and to be
more important role in supporting other industries and business. Moreover, this industry is
close to food industry that needs to utilize the packaging qualification to protect goods [1].

Since the environmental problem is one of the most important concerns of every country,
each company is heading to use green marketing. Package to pack goods is a cause of
directly environmental contamination. In other countries, particularly, the developed
countries attempt to reduce the quantity of using package, in order to reduce waste. By
optimizing cost of investment together with environmental friendly, reusable and recycle
packages, the product that has a good outstanding image can compete in the market. Thai
manufacturer and exporter should choose the material that less impacts the environment.
Thus, packaging manufacturer should pay more attention to develop production process,
including with increasing quality performance for the best quality product to satisfy the
customer. A case company employed in this study, produces flexible packaging, including all
type of printed material for food package, for example, food and snack with printing,
laminating and slitting processes.

RESEARCH OBJECTIVES
This research aims as follows:

1. To deploy six sigma approach to reduce the defective in off registration and
smearing color in printing process of flexible packaging

2. To investigate root cause and determine corrective action plan of off registration
and smearing color problems.

RESEARCH METHOD
This research employs Six Sigma approach [2], which is statistical quality control method. It
consists of 5 phases as follows:

1. Define Phase

2. Measure Phase

3. Analyze Phase

4. Improve Phase

5. Control Phase

This method is called DMAIC, as shown in Figure 1.

 Figure 1 Method to develop production process by Six Sigma approach.

Reference: http:// www.insyte-consulting.com/six sigma [3]

According to the study of Usanee Thinkohkaew [4], it was found that defective in can
production process can be reduced by applying Six Sigma approach. This is relevant with
the study of Siriwadee Aerarunchot [5], which found that contamination reduction in slider
production process by applying Six Sigma approach.

RESULTS
1. Define Phase

Define phase considers as a first step, which set a starting point and direction of research
follow by six sigma approach. It used to apply in printing process. This research purposed to
reduce printing waste from off-registration and smearing color problem.

According to the data from January’2020 to June’2020 about waste in printing process
(Figure 2) and number of customer complaint (shown in Figure 3), it was found that there
were about 14.3% of waste in printing process per month from meter of raw material film.

20
% Waste of Printing Process

18
16
1.52 1.34 Other
14 1.58 1.11 1.38
1.36 2.03 1.71 1.65
12 1.81 1.65 Splicing
1.46 1.36 2.66 2.45 2.38
10 1.25 2.29 2.37 Set up
2.31
8 2.1 4.01 4.27 Smearing
3.61 4.03 3.72
6 3.54 2.85 Off Registration
4
4.54 4.19 5.57 5.48 5.34 5.58 5.12
2
0
January February March April May June Avg.
Month

Figure 2 Percentage waste of printing process

 Figure 3 Number of customers complaint in printing process

From the Figures 2-3, off registration and smearing color problems in printing process were
chosen as a cause of problem, as there were many defects and numbers of customer
complaint. As a result, six sigma approach was used to reduce defective in off registration
and smearing color in printing process of flexible packaging and to investigate root cause, in
order to determine corrective action plan of off registration and smearing color problems.

2. Measure Phase

Measure phase will find the opportunity cause of the problem by using process map, as
shown in Figure 4. The first phase summarizes the process flow identifying the steps of the
process and the key process input variables and key process output variable to the process
steps.
 Figure 4 Process map of printing process

Gage Repeatability & Reproducibility (Gage R & R) is measurement system analysis in order
to resource can be wasted trying to improve a process when a major source of variability in
observed measurement is measurement error, the measurement system must be qualified
before beginning process improvement work and the measurement error contained in the
measurement system is only one source of variability when measuring a product of process.
In the measure phase, the team use the measurement system analysis to demonstrate that
the measurement are sufficiently accurate and precise to meet thesis objective. After that
researchers had done Gage R&R, found that Gage R & R must be more than 95% show that
measurement system analysis not error.

3. Analysis Phase

In Analyze phase, brainstorming from team member was used to get the all opportunity
cause that reference by process map. Team member put the score level in each problem to
sequence and filter the most priority cause of off registration and smearing color problem.
Cause & Effect matrix (C&E matrix) is a cause and the effect matrix related process steps to
input and correlates to process outputs and it relates the key inputs to the key outputs
using the process map. After get the results from C&E matrix (Figures 5-6), all results will
take to analyze in Failure Mode and Effect Analysis (FMEA).
 Figure 5 Cause & Effect Matrix of off registration problems

Figure 5 shows that the score in each cause of off registration problem. So eight key causes
that have total score 650 points from all 890 points (73% of all) were operator skill,
impression roller, impression roller compression, tension, register control, cylinder, oven
temperature and Bullet. These causes had been selected to analyze with FMEA.

Figure 6 Cause & Effect Matrix of smearing color problems

Figure 6 shows the score in each cause of smearing problem. So, three key causes that
have total score 280 points from all 420 points (67% of all) i.e. doctor blade, Ink cleanness
and cylinder. These causes had been selected to analyze with FMEA also.

Failure Modes and Effects Analysis (FMEA) is a methodology to evaluate failure modes and
their effects in designs and in process. The structured approach to identifying the ways in
which a product or process can fail, estimating risk associated with specific causes,
prioritizing the action that should be taken to reduce risk and evaluating design validation
plan or current control plan. FMEA was calculated the Risk Priority Number (RPN) using
equation (1);
RPN = S x O x D (1)

where

S = Severity (Importance of the effect customer requirement when 1 = not severe, 10 =

very severe)

O = Occurrence (Frequency with which a given cause occurs and creates failure modes
when 1= not likely, 10 = very likely)

D = Detection (The ability of the current control scheme to detect or prevent a given cause
when 1= likely to detect, 10 = not likely to defect)

Table 1
Failure Modes and Effects Analysis of off registration problems

Table 2
Failure Modes and Effects Analysis of smearing color problems
4. Improve Phase

After summary the score of RPN, top five from total cause of off registration problem were
Improper of impression roller quality. adjust impression roller compression off standard
condition. So, the team member had applied Quick Win method to solve and improve these
problems follow by the detail as follows.

1. Improper of impression roller quality: The root cause have two root causes such
as don’t have usage record (meter run) and don’t have procedure to measure about
impression roller hardness before use. The solution for solve this problem follow by the item
as below;

1.1. Don’t have the usage record: Set checklist to record roller usage record in
meter run and set the limit of usage that will change the new one in every 100,000 meter.

1.2. Don’t have procedure to measure about impression roller hardness: There are
two effects from this problem to off registration problem. Firstly, the roller maybe don’t
closely press down with the film and cylinder if the hardness over the standard. Another
effect is lost time to change the new roller (lost productivity) and have printing waste from
setup the machine too much. Therefore, the solutions of this problem are order the
hardness meter and set the procedure to measure the hardness of rubber roller before use
and record in checklist.

2. Adjust impression roller compression off standard, The quick win solution for
this cause is implement the printing standard condition and allowance of the pressure that
should be set at impression roller.

3. Don’t have standard condition about the tension of raw material: The quick win
solution for this cause is implement the printing standard condition and allowance of tension
that should be set at unwind and rewind unit. Otherwise, the operator should be check the
actual tension in setup and production period also.

4. Abnormal work of register control unit: This cause of problem can solve by set
the work instruction to check the register control unit in setup period (before start to
produce). Because the system will continue to automatic when start production.

5. Cylinder be ruined: Thus the team members set the procedure to check the
quality of the cylinder before and after produce. If the operators found which broken or
improper to usage, they must be sent to fixe by maintenance’s team immediately.

After summary the score of RPN, top three from total cause of smearing problem are having
scraps of Ink into block up cylinder cell and behind of doctor blade, Useful life of doctor
blade long time and don’t have rubbing cylinder. So the team member had applied six sigma
approach to solve and improve these problems follow by the detail as below.

1. Having scraps of Ink into block up cylinder cell and behind of doctor blade:
Actually, the contaminate can stick in screen of printing cylinder and doctor blade (in the
backside). The solution is install the mesh to filter the ink by use the mesh with three layer
(mesh number 40, 60, 80) in one set. The mesh can filter the contaminate in the ink and
prevent them flow in the ink tray.

2. Useful life of doctor blade long time, the action plan is change doctor blade
every 100,000 meters or before set up process

3. No have rubbing cylinder the action plan is Rub cylinder before set up produce
and store up the cylinder when printing over 100,000 meters.
5. Control Phase

After improve phase, the control plan to maintain process control was applied. The control
plan strategy is the intent of an effective control plan strategy. It operated our process
consistently on target with minimum variation and include required maintenance schedules,
as demonstrated in Table 3

Table 3
Control Plan

CONCLUSION
This research employed six sigma approach, consisting of 5 steps, which are Define Phase,
Measure Phase, Analyze Phase, Improve Phase and Control Phase. The findings found that
applying six sigma approach could reduce defect and number of customer complaint of off
registration and smearing color problems of a case study company.

From January to June’2020, waste in printing process was 14.3% per month. after applying
six sigma approach from July’2020 to February’2021, it was found that defects in printing
process could be reduced up to 50% (from 14.3% to 7.2%). When comparing with level,
it can be improved from 2.6 to 3.0 . The results also revealed that off registration
defective can be reduced from 5.1% to 2.6%, and smearing color defective can be reduced
from 3.7% to 1.4%. Therefore, if management teams control the process incessantly, waste
would be reduced continuously.
 Figure 6 Percentage waste of printing process

When comparing number of customer complaint, off registration problems can be reduced
64% (from 42 to 15 complaint) and smearing color can be reduced 75% (from 36 to 9
complaint). The results also revealed that off registration defective reduced from 5.1% to
2.6%, and smearing color defective reduced from 3.7% to 1.4%.

RESEARCH SUGGESTION
1. Suggestion from the Study

1. Due to the limitation of time frame process in this study, level can be
improved only from 2.6 to 3.0 . However, if the case company would like to increase
level for reducing to zero defect (6 level), the case company should employ six sigma
approach with other problems, for example unsmooth screen, ink dirty and off shade
problem in printing process as well.

2. The case company should provide an understanding and knowledge about six
sigma approach and other quality management for employees by arranging a training
course frequently.

2. Suggestion for Further Study

1. This research had focused only on off registration and smearing color at printing
machine no. PT-001. In the future, the case company should adopt six sigma approach with
other problems, for example, unsmooth screen, ink dirty and off shade problem in printing
process including defect from laminating and slitting process.

2. The case company should use Lean Manufacturing System applying with six
sigma approach in order to reduce lead time performance and eliminate variability in all
process.

References
Depthai, “Packaging industrial in Thailand analysis”. http://www.depthai.go.th, 2018.
Stern, T,V. Leaner Six Sigma. Making Lean Six Sigma Easier and Adaptable to Current
Workplaces, Productivity Press: NY, USA, 2019.
Insyte Consulting, “SIX SIGMA-IMPROVE PROCESSE AND SOLVE PROBLEMS”, http://
www.insyte-consulting.com/six sigma, 2008.
Thinkohkaew, U. “Defective reduction in can production process by applying Six Sigma
approach”. Master of Engineering in Industrial Engineering, Department of Industrial
Engineering, Faculty of Engineering Chulalongkorn University, 2003.
Aerarunchot, S. “Contamination reduction in slider production process by applying Six
Sigma approach”, Master of Engineering in Industrial Engineering, Department of Industrial
Engineering, Faculty of Engineering Chulalongkorn University, 2004.

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