Production & Operations Design
NMKC
Production kept failing. The fix started with the print file.
A 12% batch defect rate. Now zero — for 18 straight months.
Consecutive months with zero defect recurrence
Units shipped since the fix, zero failures
Retail launch deadlines protected since the fix
The problem
NMKC was running about a 12% batch defect rate from misalignment and bad seals. Every run put delivery dates and retail launch deadlines at risk.
The approach
We worked backward from the production line. We redesigned the specs and print files to stop misalignment and seal failures at the source, and treated it as a production problem, not a looks problem.
The results
The defect rate dropped from about 12% to 0%, and it's stayed there for 18 straight months across more than 50,000 units shipped. Every retail launch deadline since the fix has been met. A risk that used to threaten client and retailer relationships on every run is now solved for good.
Role
- Packaging & Print Spec Design
- Production Troubleshooting
Deliverables
- Packaging & print spec redesign
- Production troubleshooting
- Delivery timeline stabilization
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