Practical Application of Plan–Do–Check–Act Cycle

for Quality Improvement of Sustainable Packaging:

A Case Study
 1. Introduction
Packaging has an important role not only in increasing the customer’s satisfaction with
the product but also in improving the economic profits of a company. More than the
function of containing products inside, good packaging protects products from damages in
transport, storage, and logistics; from the end of a production line delivered over retailers,
till the end customers. Also, the packaging is an effective mean of conveying information to
customers and partners through design labels shown by product color, manufacturing date,
ingredients, characteristics, weight, user guide, etc. These results in reducing warranty and
compensation costs, increasing the customer’s satisfaction and company’ reputation. In
recent years, developing and using sustainable packaging is a global concern to protect the
environment and to reduce the burden of waste treatment for the future generation. Trends in
packaging industry development concentrate in a lower cost: Saving energy on packaging
processing; reducing raw materials; using recycled, bio-degradable material; making a
package with prolonging the durability and flexible for reuse; developing smart and
interactive packaging to consumers. This trend also poses challenges for companies in
finding new materials and packaging methods which are able to enhance their responsibility
in protecting the living environment and community but still ensure their economic returns.

There are many types of packaging material which are usually used for fragile products such
as Styrofoam, peanut foam, PE foam, bubble wrap, kraft paper, honeycomb, and
biodegradable packing made of natural, non-toxic sources such as wheat, mushroom, and
cornstarch. The common of these materials provide suitable cushioning that prevent damages
in inside areas and outside areas due to hazards and collisions during transit from the
manufacturer to customers or the retailer, or even incidents while the products are in the
manufacturer warehouse or on retail shelves. Traditional packing with Styrofoam, peanut
foam, PE foam, or bubble wrap has many advantages such as low costs, lightweight, water
insulation, easy to handle characteristics, and flexibility to return to the original shape after
absorbing shock. However, they are types of plastic which create burdens in solving problems
of long-term waste treatment, and are harmful for the environment and human health. While
different types of kraft paper, honeycomb, and biodegradable materials can be the right
solutions for these issues, they do have their disadvantages, i.e., higher weight and higher costs
than traditional packing.

Therefore, most companies are not ready to 100% replace their current package material to
biodegradable materials. Instead of using full plastics-based protectors for packaging, they try
to reduce the number of plastics and combine them with friendly environment material.

In Vietnam, current packaging methods for heavily fragile products are commonly
Styrofoam and carton box. The packaging method is simple with Styrofoam protectors for the
product corners, tops, and bottoms to prevent them from being shocked or vibrations during
transportation and handling processes. However, during the storage and transferring products
Styrofoam protectors can be broken down into small pieces due to the pressure and collision
between pallets. These are annoying for the customer when opening the box and have a lower
rating for professional packing. Increasing quality and professionalism in product packaging is
a current trend in management strategy, especially, when Vietnamese companies expand in
exporting products to Europe and developed countries. However, the extra cost for packaging
can result in significantly reduced profits of the company.

The target is how to apply PDCA methodology to tackle problems in manufacturing.

The objectives of the study focus on two main points.

The first one is to develop a simplified combination of PDCA cycle and quality tools for
quality packaging improvement.

The second one is to deploy this PDCA cycle to solve multi-objective problems for packaging
designs. The designs should guarantee protection quality, be friendly to the environment, and
contribute to manufacturing cost reduction.

Applying PDCA Cycle in Packaging for Quality Continuous Improvement

Based on its monthly reports, the primary defects caused by inadequate packaging methods
are cracks on the bottom, rim, and body of round shape fountain products. These products
have fine-stone surfaces and weight from 11 to 20 kg. In addition, the current packaging
method also is complained about using non-environmentally friendly materials. Cushions
are easily broken or displaced from the original position during transportation.

1.1.Plan
The first step in the PDCA cycle is Plan. This step includes defining problems and
collecting all relevant data. Then the team has to find out the problems’ root causes to
develop an actionable tested plan. However, identifying the key stakeholders and
understanding customers’ expectations are mainly focused first of all. Since the PDCA
requires many steps from defining, planning, testing, analyzing, etc., a multidisciplinary or
cross-functional team should be established. This team includes members who have
different main functions, who can communicate and interact with each other frequently
toward the main goal. The Plan phase normally consumes more time than others due to it
should be done very carefully in clarifying the problem, finding and analyzing the root
causes, developing solutions or countermeasures in an action plan.
Problem clarification–root cause analysis: The crack report shows the increasing percentage
of the cracked packages from the pre-shipment stage to customers’ storage checking.
Cracks appear on the rim, body, and also the bottom of products. These problems happen to
different types of products. In general, the higher percent of failure ratio, the more cost
penalty the manufacturer has to pay. Because of the damaged product, the company has to
be responsible to customer for warranty or change the new product. Especially, from the
first three months—the highest market demand duration this year, the cracks at the body,
bottom, and top of the products is 1.64%, which is extremely high compared to previous
periods. There may be a consequence of bad packaging methods or wrong manipulation that
leads to ongoing problems. In addition, current consumers and industry trends which prefer
using sustainable materials for packaging also put the company in the need of improving the
packaging sustainability. Therefore, finding the materials and packaging methods which are
friendly to the environment and still ensure bringing profit for the company are in urgent
need.

In Plan step, the re are several useful tools to improve the efficiency in team
communication and problem-solving.

5 Whys technique: The simplest tool for solving problems, developed by Sakichi
Toyoda, a Japanese inventor and industrialist. The basis of this effective approach is to
ask why five times for a specific problem. Taiichi Ohno, a famous quality guru, believes
that “by repeating why five times, the nature of the problem as well as its solution becomes
clear”. However, in general, you may need to ask the question fewer or more times than five
before the root cause of a problem is found. The meaning to strive for 5 whys is to not give
up easily until finding a root cause instead of ending up with a “symptom”. Beside be used
individually, the 5 Why technique is usually as a part of the Ishikawa diagram to identify
the causes.

A cause and effect diagram: This is also called a fishbone diagram or an Ishikawa
diagram. Using this diagram for a given problem, all its possible failure causes can be
identified, categorized, and displayed. In the diagram, the right or its head shows the
problem or effect which is identified. There is a spine, drawn by straight lines and big bones
or Ribs. These bones show the relationship between major causes and the effect. Team
members will need brainstorming (or use the first Why) to define the major causes of the
problem. Medium size bones show secondary causes, small bones represent root causes.
Ishikawa diagram is used to evaluate the root causes and to brainstorm solutions to them.
Table 2. An analysis example of grasping the actual situation, identify current problems in packaging.

For spherical shape product, the re are four

foam boards which cover all sides and are stuck
by tape. The boards are easily broken down.
Problem: Styrofoam is damaged during
storage or delivery; The flat protectors are
easily be shoved away from their initial
positions; Using unfriendly environmental
material

For rectangular cuboid type, four L shape

Styrofoam are on the top and bottom of the
product, the other four foams are placed in the
middle.
Problem: Styrofoam often is broken down in
pieces. This does not only annoy customers
but also reduce protection.

Open one box for checking: Dirty inside nylon

covered product

Outside: Boxes are bent by overloading on the top

Outside: The carton box is burst/torn or scratched by

collisions.
 Figure 2. Ishikawa diagram for possible causes creating crack.

For example, cracks on the product:

1st W: Why are they happening?
Possible causes can be bad transportation, storage or
packaging

2nd W: Why have bad packaging?

One reason can be that cushions in the packages are not good
enough.

3rd W: Why using not suitable quality cushions?

Because the company uses one type of cushion for all different types of products.
Cracks can happen on parts where the cushion is not provided enough or not thick
enough, or the shape of cushions is not fit with the product.

4th W: Why use only one type for all products?

Because cushions are not designed and tested for each type of products. There is no
instruction for using extra numbers of cushions for different sizes of shapes of
products.

5th W: Why not design and test cushion for each type of product?
The design team did simulation testing to saving cost and concluded the current
cushions can be used for a wide weight range of the products.

After evaluating current problems, finding root- causes, realizing inputs, and desired
outputs, the team has to set the target goal to lead the plan in the right direction.
 Table 4. PDCA timeline and action plan for the case study in packaging quality improvement.
PDCA Detailed Tasks
-Figure out customer
requirements for -Output: An action plan for quality improvement and to use sustainable
packaging material in packaging which includes:
-Grasp the actual -Plan to test the current packaging material and compare it with other
Plan: 2 Sept–13 situation, identify types (one or more than one) which have a competitive price
Sept current problems in -Propose a new packaging material: Minimum use of
packaging environmentally unfriendly packaging material.
-Perform root causes -Timeline to create new designs for packaging
analysis -Plan for doing real tests for materials and completed packaging of
-Set and clarify target products
goals
-Propose
solution/countermeas
ures
Carry out proposed improvement actions or
countermeasures which include:
Do: 16 Sept–20 Sept Implem -Finding new materials for packaging
ent -Using CAD/CAM software to design protectors for
actions planters and fountains
-Implement solutions to real products
Check the -Drop test to check the performance of
Check: 23 Sept–27 Sept achievements new packaging
-Verify the results
-Standardize the
improvements
-Document benefits
-Define future
Make Plans which
Act: Oct decision: include:
Adopt or
reject + Propose company
changes? to apply solutions
into real packaging
line
+ Plan for
continuous
improvements

1.2.Do
 In the Do phase, the action plan in the previous stage is carried out. The team firstly
finds new material or better-quality material for packaging which is biodegradable and
recyclable. Cardboard and honeycomb are viable materials to replace styrofoam. However,
they may create more costs, especially with honeycomb material. After doing the market
research for new viable material, price, and available suppliers, the design team decides to
use corrugated cardboard which has three to five layers. The more layers a cardboard has,
the more expensive it is. The five-layer corrugated fiberboard is used in packaging heavy
fragile products.
 Table5

is an example of how the team compares corrugated cardboard and carton boxes
from different suppliers? There are several tests to check the durable ability, resist
bursting, the strength of carton boxes and cardboards. The results from the compression
and bursting tests (Table5) show that although having the same price, the quality of carton
boxes is different from many suppliers. Ojitex carton box and cardboard are much better,
more durable than the current ones. Therefore, the team decides to use Ojitex carton
boxes and cardboards.
Table 5. Carton box testing.
Current Carton Box Ojitex Carton Box

Sample
Compression
test-results

Compression test

Bursting test Deform force (kg·f): 321.91 Deform force (kg·f): 753.98

Bursting Time Bursting force (kg·f/cm2) Time Bursting force (kg·f/cm2)

test-results
1 8.0285 1 12.6824
2 7.6124 2 14.2746
3 7.6741 3 13.6171
4 8.2956 4 14.2695
5 7.4789 5 13.1754
Average 7.8179 Average 13.6038
 Another important action in the Do phase of this case study is to change packaging
design. The new design has to maximize the advantages of new material and help in cost
reduction. Brainstorming and affinity diagram are two techniques recommended for
teamwork to generate creative solutions. While brainstorming encourages team members
to come up with ideas in a free and open environment, the affinity diagram helps to
organize these data into groupings consolidated information. Using the advantage of
science and technology in this stage helps shorten times in designing or implementing. In
this case study, mesh carton structure designed to provide both cushion and linkage
protection. This protection prevents damages from forces acting not only from sides but
also from the top and bottom of the carton box. When people load boxes to pallets and
store them in a long time, this packaging style help to balance pressure on the contact
area to all points of bottom or top side. Figure3shows a 3D packaging design using
computer-aided design software. Figure4is a real prototype of a new packaging design.

Figure 3. 3D Computer Aided Design (CAD) packaging design.

1.3.Chec
k

Figure 4. Real packaging.

 At the Check stage, the team analyzes and compares experiment results with the target
goals stated in the plan step. The check step is essentially important in decision making and
defining
further steps. For the case study, the package must resist drag, stretch, torn, and drop
conditions by manufacturer’s standard. Then, when it is delivered from the production
site to the customer’s hand, the product inside still remains its function and appearance.
In packaging protection aspect, the se factors are mandatory and considered as main
requirements to an individual package:
• Size of the box or the bottle where the object is packed inside;
• How the box can resist forces impacting on all sides;
• How it absorbs vibration and shocking condition during transporting; and
• What is the maximum protection level when the package is damaged, and whether it
still retains the original product.
Based on these factors, the team developed a drop method to test the efficiency of
the new packaging design. In this method, the packing piece (delivery packaging or master
carton) is filled and sealed for transport. It is then lifted to the designated height and held
there before it is dropped.
The number of dropping cycles to be executed: One carton box passes through 7
cycles, according to the 7-impact points (Figure5). Dropped height is the distance between
the lowest point of the packing piece and the impact surface. The height may not deviate
more than ±2% from the designated dropped height (Table6). The evaluation takes place
after the execution of all seven cycles.

Figure 5. Sequence of the impact points in dropping test.

Table 6. Dropped height for a gross weight.

Dropped Height for A Gross Weight

Content
Up to Max 10 kg Up to Max 15 kg >15 kg

Fountain 500 mm 400 mm 250 mm

 Evaluating the new packaging method: For mid-weight (under 15 kg) and round
shape products: 100% of the packing boxes withstand the dropping test condition by
absorbing shocking in both vertical and horizontal axis. This new packaging method fills the
box’s space, protects the inside product at weak points, and separates weight
concentration. It protects the inside product when vibrating and shocking. However, with
the product which weight more than 15 kg, there are still some small cracks on the top and
bottom parts.
The cost for each packaging involves a carton box, plastics foil covering the product,
and sub-items such as honeycomb board and adhesive tape. At present, the company
spends 33,644 VND for each unit packaging. The new method requires 35,684 VND. When
comparing with the current packaging method, the cost per unit of the new method
increases by 6%. This number extremely satisfies the customer’s requirement which states
that the extra cost should not be higher than 20% compared with the cost of current
packaging.
1.4.Act
In the Act phase, the team documents the results and makes the decision on adopting or
refusing the changes. Be noted that PDCA is applied for continuous improvement,
therefore, it is not a start-end process. At the Act phase, another plan to look for an even
better-improved way should be continued.
 In this case study, the new packaging design will be widely implemented for mid-
weight (under 15 kg) and round shape products. A packaging standardization process is
developed with detail task assignments (Figure6). For the large weight (above 15 kg), the
solution was not totally successful, the team rejected to applied it. Another PDCA cycle
will start again to dive further into tackling the problem.

Packaging standardization process

Workflow diagram Description Carried out by

Packing list check

Check whether products need Packaging team
to be packed after receiving leader
from Production area

Are these
product in packing list
Control on-demand packing Packaging team
products, if not, let them outside leader

Eye check Bill of

before Materials
packing (BOM) check
Check product quality and Packaging worker
materials before packing

Arrange all pre- Prepare sub-

pack products on item protectors
packaging line for individual
product Prepare packaging process Packaging worker

Pack products
with all sub- items Packaging
in box Labeling carton
box Packaging worker

Seal box and Packaging worker

load on pallet
Finish packaging
In conclusion, this example contributes understandable guidance with a successful
benchmark application of PDCA for packaging problems. It shows the art of
combining scientific methodology by utilizing tools in the PDCA cycle to achieve
multipurpose objectives i.e; responsibility in protecting the environment, increasing
quality, and economic profit as well.