Proactive quality control in

packaging line_ 6Sigma

AlAhram beverages company
_ Gouna Plant_ Keg line

Gouna plant
Member of AlAhram Beverages
Company
Allocated in Gouna Village twenty
fifth kilometer north of Hurghada city
Produce and packing Beer
Packaging : Keg line with capacity
120Kegs/ hour

Quality
2014 0.03 % Defected product
2015 0.01 % Defected product (YTD)
Used techniques : Brain storming, 5
Y analysis, Focused only on Product
Target :
Achieve and sustain 0.000% Defected
product via controlling of the
process

1_ Data Collection
Collect all defected products
Route causes for each defected
product
List all critical points ( potential
losses)
Calculate all losses

of
k
c
i
fK g
o
t
n
Par eeti
m

2_ measure the efficacy of

current Critical points

available Critical Points ( CP) on packaging line ( 32 points)

Update CP study and combine Quality matrix (QM)
Final list (45)QP

3_ Analysis of all defected

products routes cusses :
1.
2.
3.
4.

Micro contamination
Change in Chemical components
Kegs Leaking
Short fill

Defect Product
defected Process

defected Process
Defected parameter

4_Preventive actions :
1. Improve Operator skills ( Training, Practice)
2. Link between parameter to Prevent Defected
product ( 55)Parameter check ( EX :Air pressure,
heat temp, flow rate, flow detection,,,)
. 3_ Create a map for all defected modes

5_Control preventive
actions
Created a annual control plan to
sustain the results