{"id":13608,"date":"2025-06-18T09:08:18","date_gmt":"2025-06-18T08:08:18","guid":{"rendered":"https:\/\/www.theleansixsigmacompany.com\/tlssc-preview3\/?p=13608"},"modified":"2026-02-10T08:56:14","modified_gmt":"2026-02-10T07:56:14","slug":"streamlining-machine-settings-for-efficiency-in-packaging","status":"publish","type":"post","link":"https:\/\/www.theleansixsigmacompany.com\/uk\/library\/streamlining-machine-settings-for-efficiency-in-packaging\/","title":{"rendered":"Streamlining Machine Settings for Efficiency in Packaging"},"content":{"rendered":"
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Industry:<\/span><\/strong>\u00a0<\/strong>Consumer<\/span> Goods<\/span><\/div>\n
Department:<\/span><\/strong> Packaging<\/span><\/div>\n
Project\u00a0Duration:<\/span><\/strong> 12 months<\/span><\/div>\n<\/div>\n
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Financial\u00a0Benefits:<\/span><\/strong> Estimated savings of $15,000 (converted from \u20ac15,000)<\/span><\/div>\n
Type of\u00a0<\/span>Project:<\/span><\/strong> Green Belt Project<\/span><\/div>\n

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This project aimed to optimize machine settings for a packaging department in the consumer goods industry. By applying Lean Six Sigma methodologies, specifically the DMAIC<\/a> (Define, Measure, Analyze, Improve, Control) approach, the team targeted a pressing issue that disrupted production and increased costs: excessive adjustments to the machine\u2019s servo-driven settings. This project illustrates how Lean Six Sigma tools can provide solutions to complex manufacturing problems while achieving significant cost savings and efficiency gains.<\/p>\n

The Challenge: Reducing Machine Adjustments<\/strong><\/h3>\n

The project team focused on a packaging machine that reverted to default settings after every batch load. Each batch required an average of six additional adjustments, adding time and resources to ensure the equipment operated correctly. This problem not only hampered productivity but also frustrated team members who constantly dealt with interruptions. Following discussions with a project sponsor and department managers, the goal was set to reduce these manual adjustments by 75%, which would allow the machine to run with minimal intervention.<\/p>\n

Setting Up the Project Team<\/strong><\/h3>\n

A critical success factor in this Lean Six Sigma project was forming a well-balanced team with individuals who understood both the machine operations and the broader goals. The team included experienced operators from each shift and a formulation manager. Including operators in the process proved to be strategic, as their insights into daily operations provided essential data that helped guide the project\u2019s progress.<\/p>\n

Assembling the team required careful consideration of team roles, leadership dynamics, and individual motivation levels. Early on, it became apparent that including operators from different shifts would foster cross-team understanding and bring a range of perspectives on the machine\u2019s behavior. Their input was valuable, as they had a direct stake in the project\u2019s success and were instrumental in identifying operational inefficiencies. Lean Six Sigma projects emphasize teamwork and engagement, and this project reinforced that including front-line workers adds depth to the problem-solving process.<\/p>\n

Tools and Techniques Used<\/strong><\/h3>\n

The DMAIC structure guided the project, helping to break down complex issues into manageable phases. To identify root causes of the excessive machine adjustments, the team applied several Lean Six Sigma tools:<\/p>\n