Root cause analysis and solution of a quality problem

(Troubleshooting, Packaging optimization)

An increasing problem, ranging from tears of a few millimeters to complete rupture, was observed with print-mark-controlled aluminum foils for tablet blister packs on several different, but structurally identical packaging machines. The machines and the aluminum foils had been used unchanged over a period of many years without any problems. The possible cause of the tearing was eventually found after extensive and complex troubleshooting involving microscopic tests undertaken at Munich University of Applied Sciences. As a result, the client was able to prepare a facts-based complaint and solve the quality problem.