1.

Project Overview:
o Project Name: “Laminate Leakage Reduction in Snacks Industry.”
o Problem Statement: Describe the current issue related to laminate leakage in
snack packaging.
o Purpose: Explain why addressing this issue is crucial (e.g., product quality,
cost reduction).
o Business Case: Highlight the benefits of reducing leakage (e.g., improved
customer satisfaction, waste reduction).
2. Scope:
o Define the boundaries of the project. Specify which aspects of the snacks
industry and packaging process are included.
o Identify any exclusions (what’s not part of the project).
3. Goals and Objectives:
o Clearly state what you aim to achieve (e.g., reduce leakage by 0.5%, enhance
packaging integrity).
o Set measurable objectives (quantifiable targets).
4. Metrics and Success Criteria:
o Define how you’ll measure success (e.g., leakage rate, customer feedback).
o Specify acceptable thresholds.
5. Stakeholders:
o List key stakeholders (e.g., production team, quality control, management).
o Include their roles and responsibilities.
6. Project Schedule:
o Tentative timeline for the project (start and end dates).
o Milestones (e.g., testing phase, implementation).
7. Resources:
o Identify necessary resources (personnel, equipment, budget).
o Consider any external expertise needed.
8. Cost-Benefit Analysis:
o Estimate costs (materials, testing, training).
o Quantify benefits (reduced waste, improved product quality).
9. Risks and Constraints:
o List potential risks (e.g., resistance to change, technical challenges).
o Note any constraints (budget, time limitations).
10. Assumptions:
o Document any assumptions made during project planning.

What is Laminate
1. Why Use a Pouch Laminator?
o Longevity of Materials: Laminating extends the lifespan of teaching materials,
making them more durable.
o Enhanced Visual Appeal: Laminated items have a professional finish, enhancing
colours and making images pop.
o Reusability: You can write on laminated items with dry-erase markers and wipe them
clean.
2. Laminating Pouch Thickness:
o Pouch thickness is measured in microns (1 micron = 1000th of a millimetre).
 o Thicker pouches (e.g., 5 mil) provide more rigidity and durability compared to
thinner ones (e.g., 3 mil).

Types of Leakage
When it comes to analysing leakage in laminate packaging, it’s essential to understand
that seal quality tests play a crucial role. These tests assess the quality and consistency of
seals, providing some assurance of the package’s ability to remain intact. However, it’s
important to note that passing a seal quality test doesn’t necessarily mean the package is leak-
free.

1. Seal Quality Tests (SQT):

o Purpose: Characterize and monitor seal quality.
o Parameters Monitored:
 Seal quality or characteristics.
 Package materials.
 Package components.
 Sealing process.
o Examples:
 Heat seal strength: A pouch with a strong heat seal peel force may still
have a pinhole in the pouch face.
 Closure application force: A well-closed capped bottle may leak due to
a scratch on the bottle finish.
o Failing SQT: Indicates a package integrity risk (e.g., weak heat seal peel force
increases the likelihood of leakage during the product life cycle).
2. Closure Application and Removal Force:
o Description:
 Application force: Torque required to apply a screwcap onto a threaded
closure.
 Removal force: Torque required to initiate screw-cap removal.
o Correlation to Package Integrity:
 Well-closed caps are less likely to back off during the product life
cycle and leak.
 Over-closed caps may distort components, causing damage and
leakage.
3. Package Burst Strength:
o Description: Pressure at which a package ruptures during exposure to
increasing internal air pressure.
o Correlation to Package Integrity:
 Low burst strength packages are more likely to rupture during the
product life cycle.
 Indicates sealing process failure or material changes.
 Mode of rupture (bond vs. edge) provides insights into seal failure
risks.

Remember that seal quality tests and package leak tests work together to ensure overall
package quality. If you need further details or have specific requirements related to laminate
packaging, consulting with packaging experts is recommended!
 What is Root cause
Let’s explore the root causes of quality issues and rework in various contexts:
1. Manufacturing:
o Common sources of errors include:
 Faulty equipment: Malfunctioning machinery or tools.
 Flawed design: Design flaws leading to production issues.
 Miscommunication: Lack of clear instructions or misunderstandings.
 Human error: Mistakes made during production processes.
o To minimize rework, understanding these errors and implementing preventive
measures and robust quality control systems is crucial
2. Construction:
o Causes of rework in construction include:
 Inadequate quality management: Insufficient quality control and
monitoring.
 Misinterpretation of plans and specifications: Work not aligned
with documents.
o Clear communication and effective quality assurance can help avoid rework

Cost Impact of wastage

When it comes to the snack industry and packaging, understanding the cost impact of
wastage is crucial. Let’s focus on retort pouches, which are commonly used for food
products. Here’s how they relate to wastage and their environmental impact:
1. Retort Pouches Overview:
o What Are Retort Pouches? Retort pouches are robust, flexible packaging designed
to withstand high-temperature sterilization. They combine the durability of traditional
cans with the flexibility of modern materials.
o Materials Used: These pouches are made from a composite of materials like plastics
and metal foils. These materials block moisture, light, and air, preserving food quality
and flavor.
2. Benefits of Retort Pouches:
o Extended Shelf Life: Retort pouches provide an airtight environment, minimizing
contamination risk and significantly extending shelf life compared to traditional
packaging methods.
o Improved Taste and Nutrient Retention: High-temperature sterilization preserves
taste and nutritional quality more effectively than traditional canning.
o Lightweight and Space-Efficient: Flexible pouches take up less storage and
transportation space, reducing logistics costs and environmental impact.
o Enhanced Branding Opportunities: Large, smooth surfaces allow for high-quality,
customizable printing, making products stand out on shelves.
3. Environmental Impact and Wastage:
o Reduced Environmental Impact: Retort pouches generally have lower
environmental impacts than aluminium cans for ready-to-eat foods.
o Packaging and Washing Processes: Both retort pouches and cans contribute to
environmental impact, but retort pouches fare better overall.
o Plastic Concerns: While retort pouches reduce material waste, it’s essential to
address plastic pollution. Plastic fibres are found even in tap water, affecting human
health and ecosystems.
 DMAIC
A DMAIC project charter is a crucial document for Six Sigma projects. Let’s create one
specifically for addressing laminate pouch leakage in the snacks industry. Here are the
essential components:
1. Define Phase:
o Problem Statement: Clearly define the issue related to laminate pouch leakage.
Specify the location (e.g., production line) and process involved.
o Frequency and Impact: Provide supporting facts, such as how often leakage occurs
and its financial impact on the business.
o Scope: Focus solely on the area of concern without assigning blame or suggesting
solutions1.
2. Measure Phase:
o Baseline Measurement: Collect data on current leakage rates and identify key
metrics.
o Process Mapping: Map out the entire process involved in pouch production and
identify critical points where leakage may occur.
3. Analyze Phase:
o Root Cause Analysis: Investigate potential causes of leakage. Use tools like fishbone
diagrams or Pareto charts to identify root causes.
o Data Analysis: Analyze data to pinpoint specific factors contributing to leakage.
4. Improve Phase:
o Solutions: Propose solutions to address leakage. Consider process modifications,
material changes, or equipment adjustments.
o Risk Assessment: Evaluate potential risks associated with implementing changes.
5. Control Phase:
o Monitoring Plan: Define how you’ll monitor leakage going forward. Set up control
charts or other monitoring mechanisms.
o Standard Operating Procedures: Document revised procedures to prevent leakage.
o Training: Train relevant personnel on the new procedures.