Case Studies The Sweet Smell of Success

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	The Sweet Smell of Success

The Sweet Smell of Success

Technology Category	Analytics & Modeling - Predictive Analytics Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries	Consumer Goods Retail
Applicable Functions	Quality Assurance
Use Cases	Predictive Maintenance Process Control & Optimization
Services	Software Design & Engineering Services System Integration Training
Challenge	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 realization provided a significant opportunity to reduce overfill and save money. However, the company did not have enough historical data on the lines that were overfilling to understand the entire problem. This meant that process engineers and quality professionals did not have sufficient information to develop a viable solution. 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 its SPC Fill Height Project, Coty wanted to determine ways to reduce liquid scrap and better understand its process capability. Read More
About Customer	Coty, a leader in the global beauty and fragrance industry, was founded in Paris in 1904 by François Coty. The company today exhibits innovation and a drive to quickly capture emerging trends, creating enduring brands that speak to the aspirations and lifestyles of today’s consumers. That spirit of innovation leads Coty to pursue continuous improvements in all its operations. Driven by passion, creative freedom, and an entrepreneurial spirit, Coty has built a unique portfolio of beauty brands that include some of the strongest consumer franchises in history. The company’s products span fragrances, color cosmetics, and skin and body care. Coty has an annual revenue of over $8 billion, is headquartered in New York City with offices in more than 35 countries, and employs 19,000 people worldwide. The company has a global manufacturing presence with Research and Development Centers of Excellence, 8 manufacturing facilities, and locations in Europe, the United States, and China. Read More
Solution	Coty approached InfinityQS, the global authority on manufacturing quality management, about implementing its proven Quality Intelligence software—powered by a centralized SPC analysis engine—at its Sanford facility. Coty used InfinityQS Professional Services to help ensure the most effective deployment of the solution. Leveraging the skills and experience of InfinityQS’ certified quality engineers, industrial statisticians, and Six Sigma Black Belts, Coty implemented its SPC Fill Height Project incrementally across 12 fragrance lines. The company set target amounts for every SKU (2,600 parts), control limits for each product and line combination (filling variation), and specification limits (min and max fill height levels). The implementation process also included training for more than 100 users, from line operators and quality inspectors to managers and directors. This highly focused, customized training helps promote a positive adoption of the new solution by users, ensuring they enjoy the benefits of the new tools at their disposal. Training also helps ensure the company gets the greatest value from its software investment. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Predictive Analytics

Functional Applications - Manufacturing Execution Systems (MES)

Applicable Industries

Consumer Goods

Retail

Applicable Functions

Quality Assurance

Use Cases

Predictive Maintenance

Process Control & Optimization

Services

Software Design & Engineering Services

System Integration

Training

Challenge

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 realization provided a significant opportunity to reduce overfill and save money. However, the company did not have enough historical data on the lines that were overfilling to understand the entire problem. This meant that process engineers and quality professionals did not have sufficient information to develop a viable solution. 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 its SPC Fill Height Project, Coty wanted to determine ways to reduce liquid scrap and better understand its process capability.

About Customer

Coty, a leader in the global beauty and fragrance industry, was founded in Paris in 1904 by François Coty. The company today exhibits innovation and a drive to quickly capture emerging trends, creating enduring brands that speak to the aspirations and lifestyles of today’s consumers. That spirit of innovation leads Coty to pursue continuous improvements in all its operations. Driven by passion, creative freedom, and an entrepreneurial spirit, Coty has built a unique portfolio of beauty brands that include some of the strongest consumer franchises in history. The company’s products span fragrances, color cosmetics, and skin and body care. Coty has an annual revenue of over $8 billion, is headquartered in New York City with offices in more than 35 countries, and employs 19,000 people worldwide. The company has a global manufacturing presence with Research and Development Centers of Excellence, 8 manufacturing facilities, and locations in Europe, the United States, and China.

Solution

Coty approached InfinityQS, the global authority on manufacturing quality management, about implementing its proven Quality Intelligence software—powered by a centralized SPC analysis engine—at its Sanford facility. Coty used InfinityQS Professional Services to help ensure the most effective deployment of the solution. Leveraging the skills and experience of InfinityQS’ certified quality engineers, industrial statisticians, and Six Sigma Black Belts, Coty implemented its SPC Fill Height Project incrementally across 12 fragrance lines. The company set target amounts for every SKU (2,600 parts), control limits for each product and line combination (filling variation), and specification limits (min and max fill height levels). The implementation process also included training for more than 100 users, from line operators and quality inspectors to managers and directors. This highly focused, customized training helps promote a positive adoption of the new solution by users, ensuring they enjoy the benefits of the new tools at their disposal. Training also helps ensure the company gets the greatest value from its software investment.

Impact #1	Coty found that it could now easily analyze all necessary Key Performance Indicators (KPIs) on control charts for easy interpretation and analysis.
Impact #2	The company eliminated the need for overproduction of liquid to compensate for overfilling.
Impact #3	Differentiated special-cause variation from natural variation with real-time information about the process.

Impact #1

Coty found that it could now easily analyze all necessary Key Performance Indicators (KPIs) on control charts for easy interpretation and analysis.

Impact #2

The company eliminated the need for overproduction of liquid to compensate for overfilling.

Impact #3

Differentiated special-cause variation from natural variation with real-time information about the process.

Benefit #1	Saved $270,000 by eliminating overfilling through more accurate control of fill heights.
Benefit #2	Realized more than $220,000 in ROI.
Benefit #3	Initial investment of $47,000.

Benefit #1

Saved $270,000 by eliminating overfilling through more accurate control of fill heights.

Benefit #2

Realized more than $220,000 in ROI.

Benefit #3

Initial investment of $47,000.

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Overview

The Sweet Smell of Success

Operational Impact

Quantitative Benefit