GH6581 Packaging Box Abnormality Analysis Report

Quality control is not only about catching defects but also about implementing practical corrective actions to prevent recurrence. This report explores the GH6581 packaging box abnormality incident, analyzing the root causes, immediate actions, and long-term corrective measures that improved the production process and restored client confidence.

Background and Team Composition

The issue in question was raised after the client identified defective packaging boxes. To address this, a cross-functional improvement team was formed, involving members from the Sales, Quality, Production, Engineering, and PMC departments. Key personnel included:

This diverse team was tasked with conducting a detailed analysis and implementing robust countermeasures.

Interim Actions Taken

To prevent further defects while the investigation was ongoing, the following interim actions were implemented:

Production Process Overview

The production process for the GH6581 packaging box involves multiple stages, each critical for ensuring quality:

1. Box Sleeve Die-cutting and Waste Removal

2. First Gluing of Box Sleeve Edges

3. Second Gluing for Box Sleeve Forming

4. Full Inspection after Assembly

5. Packing

The root cause was later traced back to the second gluing stage, where bonding strength was insufficient.

Root Cause Analysis

After a detailed on-site inspection and collaboration with the client, the following root causes were identified:

• Primary Cause: During the second gluing process, the gluing position at the box opening was too close to the first gluing position. This led to insufficient pressure bonding, leaving areas unsealed.

• Secondary Cause: The weak adhesion (false bonding) was not detected during final inspection, allowing defective boxes to pass through assembly and reach the client.

This highlighted a need for process modification and enhanced inspection protocols.

Corrective Actions Implemented

The corrective actions were designed to eliminate the defect and strengthen quality assurance procedures. Key measures included:

1. Integration of an Additional Pressing Machine
   After the second die-cutting, a pressing machine was added to reinforce glue adhesion during the forming and gluing stage.

• Date: 3.21

• Responsible: Zhang Dahua

• Status: Completed

2. Enhanced Quality Testing Protocol
   On-site tests for glue bonding strength were implemented, with every 200 pcs undergoing break-strength testing. Any abnormalities triggered immediate glue and pressure adjustments.

• Date: 3.21

• Responsible: Zhang Dahua / Ren Jinna

• Status: Completed

3. Training and Process Awareness
   A training session was organized for assembly personnel to raise awareness about glue opening defects. Client feedback was shared to prevent recurrence.

• Date: 3.21

• Responsible: Tan Sizai

• Status: Completed

Outcomes and Lessons Learned

Following the implementation of these corrective measures, the GH6581 packaging box production line reported zero recurrence of the defect. Client trust was restored, and the case served as a valuable lesson in root cause investigation and proactive quality improvement.

Key takeaways include:

• Continuous monitoring during critical process stages (such as secondary gluing) is essential.

• Real-time testing and immediate corrective action can prevent large-scale defects.

• Cross-functional collaboration accelerates problem resolution and enhances accountability.

Moving Forward

The GH6581 case underlines the importance of a structured approach to defect management in packaging manufacturing. Future improvements will include:

• Automated adhesive strength sensors during gluing stages.

• Stricter visual and tactile inspection protocols.

• Ongoing training programs for assembly and QC teams.

This comprehensive approach ensures not only product quality but also strengthens long-term partnerships with clients.