FMCG Quality Control Redesign, Ogun State
Emeka Okonkwo
Process Engineer, Nestlé Nigeria
Plain language
A fast-moving consumer goods plant in Ogun State was reporting an 8.2% end-of-line defect rate on beverage packaging — more than 8× the acceptable industry threshold. Root cause analysis had been attempted three times with no lasting improvement. Each investigation treated symptoms, not the system.
SE approach applied
Six Sigma DMAIC framework applied at the system level: defined value stream from raw material intake to finished goods. Statistical Process Control (SPC) charts to identify variation sources. Design of Experiments (DoE) to isolate critical control variables. Revised measurement system analysis to ensure gauges were calibrated.
Disciplines Applied
Impact & results
Defect rate reduced from 8.2% to 0.9% within one production quarter. Estimated annual savings of ₦180 million from reduced waste and rework. Plant subsequently adopted the DMAIC approach as its standard quality intervention method.
Emeka Okonkwo
Process Engineer, Nestlé Nigeria
Published by
ASES · UNILAG
Association of Systems Engineering Students