Going Beyond Six Sigma

Project Detail

Client: A manufacturer of checks

Business Area: Multiple manufacturing plants

Opportunity: Reduce the rare but critical rate of “non-public information” errors (NPIs) caused by “flipped and folded sheets” that occur in the printing process

Approach: Initial error rate (across all plants) averaged four per month; project identified potential causes and used a Design of Experiments (DOE) approach to confirm root causes, then designed preventative actions


  • Designed and implemented solutions in machine setup, operational procedures, and accountabilities
  • Reduced overall NPI errors for the company by 75%
  • Reduced NPI errors for that defect type to zero

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