Coty eliminated overfill to save $270,000 with SPC Fill Height Project

As part of continuous improvement efforts, Coty determined that its filling process was generating a higher level of waste than expected. This was due in part to some lines overfilling containers to ensure aesthetic fills were met, which led to higher expenses on supplies. Considering the price of some of the fill liquids, this was a significant opportunity to reduce overfill and save money. However, the company did not have enough historical data on these lines, which meant that process engineers and quality professionals did not have sufficient information to truly understand the entire problem and develop a viable solution. In 2010, the manufacturing team at Coty’s Sanford, North Carolina, manufacturing facility turned to Statistical Process Control (SPC) analysis to better understand scrap at the point of manufacture on its filling lines. As part of an SPC Fill Height Project, Coty wanted to determine ways to reduce liquid scrap and better understand its process capability.

Coty is a leader in the global beauty and fragrance industry. Founded in Paris in 1904 by Francois Coty, the company today exhibits innovation and a drive to quickly capture emerging trends, thereby creating enduring brands that speak to the aspirations and lifestyles of today’s consumers. The company boasts an annual revenue over $4 billion, is headquartered in New York City with offices in more than 30 countries, and employs 10,000 worldwide. Coty’s global manufacturing presence, including Research and Development Centers of Excellence and eight manufacturing facilities, is spread across locations in Europe, the United States, and China. Driven by passion, creative freedom, and an entrepreneurial spirit, Coty has built a unique portfolio of beauty brands that have produced some of the strongest consumer franchises in history. The company’s products span three categories of fragrances, color cosmetics, and skin and body care, with adidas, Calvin Klein, OPI, philosophy, Chloé, Davidoff, Playboy, Rimmel, Marc Jacobs, and Sally Hansen comprising its top 10 brands. The full product portfolio is sold through distribution channels that include upscale department stores, specialty retailers, upscale perfumeries and pharmacies, mass-market retailers, duty-free shops in airports and cities, QVC, and various e-commerce channels.