Quality assurance in light incontinence products

Abstract

The master’s thesis investigates the procedure of specifying and monitoring the key materials Super Absorbent Polymers (SAP) and pulp in light incontinence products at Essity. The project focuses on four phases within the value chain from product development, design verification, process validation to running production. The aim was to evaluate existing procedures to identify potential gaps and opportunities for improvement. The research approach was based on the DMAIC framework originating from the Six Sigma philosophy, integrating qualitative methods and data from semi-structured interviews, workshops with quantitative data from laboratory testing on prototype products. Statistical tools were also implemented to analyze variation and correlation and to perform capability studies. The study identified that variation in SAP and pulp amount and distribution affects the product performance. Due to process-related influences, such as environmental conditions and technical factors, variation will always be present in the production system. Therefore, the importance of robust design strategies was highlighted together with the value of proper monitoring of SAP and pulp amount and distribution across the value chain. Control measures based on gathered information were proposed to enhance process control and stability, emphasizing the importance of centering processes around target values rather than only specification limits. While the limited sample size and test scope restrict broad generalization, the results provide a solid foundation for further investigation and practical improvements when it comes to quality assurance. Additionally, the research highlights the value statistical tools can bring within the organization to sustain quality improvements. Overall, this thesis contributes to a deeper understanding of SAP and pulp management in hygiene products and supports Essity’s efforts to optimize product consistency and customer satisfaction through data-driven quality control