Transforming Quality through Lean Six Sigma Black Belt methodology: Why we must revolutionize our approach to product failures

Quality issues aren’t just complaint, they're a path to losing market share

Research shows that 91% of sad customers leave without saying their issues. For Asaleo Care, the 350 monthly complaints signalled a threat to brand’s image.

Did you know that, according to PwC, 32% of customers stop trading after just one bad experience? What impact do hundreds of monthly complaints have on long-term customer trust and loyalty?

How often do companies overlook complaints as isolated cases rather than warnings of losing market share? If this persists, how soon will competitors take advantage?

Why quality matters to you and your business?

Customer complaints reflect on your business and impact both your reputation and bottom line. Ensuring high product quality using advanced statistical tools and delivering Six Sigma Black Belt project is essential to avoid failures, safeguard your brand, and secure the future success of your business.

The costly challenge: Tackling adhesive failures head-on

Asaleo Care was losing ground to a pervasive problem—weak adhesive in nappies.

Complaints were skyrocketing, and the root cause remained elusive.

Traditional quality checks weren’t enough to catch the cause ,leading to external failure costs piling up.

The challenge was clear: Deliver Six sigma Black Belt project using advanced statistical analysis tools to identify and eliminate the problem at its core.

Imagine zero complaints and a stronger Brand

What if we could eliminate your complaints altogether?

  • Imagine a scenario where your products leaving the line meeting the expectations of your customer.
  • Reducing the cost of external failures would not only save money but also elevate the brand’s reputation.
  • This is the future we can achieve, where Asaleo Care stands as a leader in market.

Uncover my three parallel pillars: Plan + Improve + Control

  1. Quality Planning
    The main goal was to build quality into the product or process right from the beginning.
  2. Quality Control
    The aim was to detect and correct deviations to maintain the planned level of quality.
  3. Quality Improvement
    We were focused on achieving a higher level of quality by making significant changes to our manufacturing process

Excellence = Plan + Improve + Control

  • Set objective
  • Establish testing protocol
  • Develop process design
  • Communicate plan

Excellence = Plan + Improve + Control

  • We assessed adhesive strength and glue weight using Six Sigma Black Belt techniques such as control charts and real-time monitoring to ensure targets were met
  • We analysed glue weight against target and identified inconsistencies
  • We addressed discrepancies by adjusting RPM and improving operator training, leading to consistent adhesive strength and quality

Excellence = Plan + Improve + Control

  • The business received 350 monthly complaints about weak adhesive
  • I led a Six Sigma Black Belt project to tackle the adhesive issue
  • I developed a sampling plan to collect data
  • I  Collaborated with teams to improve the process
  • I used Minitab to identify RPM as the key factor in glue weight
  • I Standardized the process using an Excel tool for RPM settings

How our strategy built a future-proof quality system?

Our strategy focused on delivering Six Sigma Black belt project , scalable solutions to enhance product quality. By leveraging advanced statistical analysis tools and real-time monitoring, we identified and addressed key factors affecting quality. Continuous improvement processes and robust training ensured that our quality systems adapt to evolving needs, maintain high standards, and remain resilient against future challenges.

  • Schedule a Consultation: Let us show you how to eliminate inefficiencies and drive measurable improvements by using advanced statistical analysis tools such as Multi Variable Eregression analysis in our AI-Driven Six Sigma black Belt course
  • Learn from Asaleo Care’s Success: Download our detailed case study to see the exact steps we used to achieve faster project completion.
  • Start Your Transformation Today: Reach out to discuss how we can tailor these solutions for your team.
  • Click button to book your first strategy session and take the first step toward consistency, efficiency, and success.