At Jiaxing Yuhong Technology Co., Ltd., quality is not just an inspection result; it’s a system of accountability, continuous learning, and customer trust. When a color variation defect appeared in a batch of printed boxes for a major client, the company treated the issue as an opportunity to refine its production discipline and reinforce its process controls.
This case study summarizes how the team handled the situation, from problem identification to root cause analysis, corrective action, and long-term improvement, following the company’s structured Quality Abnormality Improvement Report (D1–D8) process.
Client: Zhongrong
Report No.: 20240621001
Product: FSC-Rigidbox Gillette Venus 1 Razor Handle + 4 Blades + 1 Base (Tmall 2)
Product Code: A004008393
Work Order No.: WO24060033
Delivery Quantity: 2,049 pcs
Defective Quantity: 2,049 pcs
Defect Rate: 100%
Abnormal Type: Customer Complaint
The client discovered the issue during the incoming inspection, which noted color variation on the outer packaging. Every piece in the batch was considered nonconforming, triggering an immediate internal review.
The customer identified that the outer box surface color was inconsistent, deviating from the approved standard sample.
Responsible Department: Production
Loss Responsibility: 100% borne by Production
This was classified as a customer complaint abnormality, meaning the case required immediate root cause analysis and verified corrective measures before resuming production.
After on-site confirmation, the company determined that the affected products could not be reworked or reprinted effectively, and therefore chose scrap disposal as the proper handling method.
At the same time, the Quality Supervisor (Wang Chunmao) and Department Manager (Yang Siyong) initiated the root cause analysis process, requiring the production and printing teams to propose corrective and preventive actions within 24 hours.
The investigation combined client feedback, production record review, and on-site verification. The analysis revealed several key points:
First-piece verification was compliant:
The first printed sample matched the approved color standard, eliminating first-piece setup as the cause.
Partial defects in semi-finished goods:
Remaining semi-finished products in stock showed similar defects, confirming the issue occurred during mass production — not across the entire batch.
Printing process deviation:
The printing team review concluded that the press operator failed to add diluent in time during mass production. As a result, ink thickened and the printing plate became clogged, producing images that appeared faded or merged with the background color.
Conclusion:
The root cause was human error — improper machine operation and lack of timely inspection during the print run. While the first-piece sample was correct, the operator failed to monitor in-process color drift, allowing the defective prints to escape detection.
Responsible Department: Production Department
To contain the issue and protect client operations, Jiaxing Yuhong implemented immediate corrective actions:
Client coordination and product return:
Communicated the issue transparently, isolated all defective goods, and arranged for return and remanufacture.
Internal isolation and scrapping:
All semi-finished goods in inventory were quarantined and scrapped to avoid accidental mixing.
Urgent re-production:
All departments collaborated to complete urgent reprints, ensuring the client’s production line was not interrupted.
Responsible Persons:
Yang Jinlian – Completed 2024/06/21
Wang Chunmao – Completed 2024/06/21
After addressing the immediate issue, the company developed structured preventive measures to ensure the similar problems would not recur:
First-piece and in-process verification system:
Printing supervisors and machine operators were retrained to adhere strictly to client-provided color standards. Production must now include color checks every 300 sheets, with results verified by quality patrol staff.
Diluent control standardization:
Any color deviation during production requires an immediate adjustment of 3–4g of diluent. Suspected defective sheets are to be isolated, labeled, and 100% inspected after printing. All confirmed faulty items are scrapped.
Inspection training and sampling frequency:
Quality and printing staff now perform joint training on visual color judgment techniques. In addition, finished goods sampling is increased to every 1,000 pcs/hour. Any abnormality triggers a stop-and-verify process before production continues.
Responsible Departments: Production / Quality
Completion Date: 2024/06/21
Responsible Persons: Yang Jinlian, Wang Chunmao
To ensure sustainable quality control, Jiaxing Yuhong established long-term preventive systems:
Leadership and awareness training:
All printing and production leaders participated in workshops emphasizing the impact of color variation and print clarity on client satisfaction.
Cross-departmental process learning:
All production employees and key staff received hands-on training on print quality criteria, inspection standards, and defect judgment. Any adjustment pieces or anomalies must be immediately isolated and evaluated by designated inspectors.
Quality culture reinforcement:
Each workshop now features quality notice boards showing real photos of customer complaints. These serve as constant visual reminders, strengthening quality awareness and encouraging active participation from all employees.
The management team emphasized follow-up verification over multiple batches before case closure:
The corrective actions would be tracked across three consecutive production batches.
If no further abnormalities occurred, the case would be formally closed as resolved.
Reviewed By:
Department Manager: Yang Siyong
Quality Department: Wang Chunmao
This case demonstrates how Jiaxing Yuhong Technology Co., Ltd. transforms a customer complaint into a learning and improvement process. Through disciplined root cause analysis, structured corrective action, and continuous operator training, the company strengthened its color control system and reduced the risk of similar printing deviations.
The event reinforced Yuhong’s belief that quality improvement is not about eliminating mistakes, but about systematizing the way they are handled. Each incident presents an opportunity to enhance awareness, process rigor, and cross-departmental collaboration, ensuring that every product consistently meets client expectations for excellence.