Process Improvement in a Sachet Water Production Unit in Imo State

This project evaluates and proposes improvements for the production process of a sachet water manufacturing unit in Imo State, South East Nigeria. Sachet water production is a widespread small-scale industry across Nigeria, providing affordable drinking water to millions of urban and peri-urban consumers; however, the sector is characterised by inconsistent process standards and high rates of product rejection due to sealing defects and microbiological contamination. This research employs process flow analysis and cause-and-effect diagram construction to systematically identify sources of production inefficiency and quality failures. Data were collected through structured observation of the production line, measurement of defect rates across three shifts over five weeks, and interviews with machine operators and the quality supervisor. Findings reveal that approximately twelve percent of daily sachet output is rejected at the sealing inspection stage, with heat sealer temperature fluctuation and worn sealing wires identified as the primary root causes. Further analysis identifies inadequate incoming water pre-treatment as a contributor to microbiological rejection. Recommendations include a temperature calibration schedule for all heat sealers, a planned replacement programme for sealing consumables, and upgrading the pre-treatment stage to include ultraviolet disinfection. Estimated rejection rate reduction following implementation is projected at seventy percent of current levels. Keywords: process improvement, sachet water, sealing defects, cause-and-effect diagram, Imo State