Context: A packaging defect was causing leakage in transit across a high-volume EMEA product range, creating returns, customer dissatisfaction and wider order-contamination risk.

Challenge: The issue required immediate containment to protect customers, but also a robust root-cause fix involving production, engineering and suppliers.

Role: Led a cross-functional DMAIC project bringing together production, engineering, supplier quality and packaging suppliers to identify the design drivers, validate the changes and implement a permanent fix.

Outcome: Defects reduced by 79%, sigma improved from 3.9 to 4.4, reject cost fell by 84%, order-damage exposure reduced by 84%, containment was removed and the issue did not recur.