<![CDATA[General Background Quality control plays a vital role in liquid soap manufacturing to minimize defect rates and satisfy consumer expectations. Specific Background Refill liquid bodywash packaging lines encounter substantial quality deviations during manual filling and assembly processes. Knowledge Gap Existing research lacks quantitative diagnostic insights regarding root causes of defects in high-volume liquid packaging systems. Aims This investigation applies statistical quality control tools to systematically identify primary defect categories and underlying operational failure modes within a dedicated production line. Results Out of 60,792 total produced units, analysis reveals 1,574 defective packages, where untidy sealing accounts for 36% and tilted sealing represents 30% of total failures, alongside missing lot codes (29%) and leaks (5%). Statistical control charts indicate out-of-control conditions on days 6 and 10, while cause-and-effect diagrams link these errors to inadequate press maintenance, unstable sealing temperature, and operator fatigue. Novelty This work establishes empirical control thresholds and multi-factor cause mappings specifically tailored to manual refill packaging operations. Implications Implementing targeted machine maintenance schedules and operator ergonomics directly decreases defect occurrence and improves manufacturing yield. Key Findings Highlights Untidy and tilted sealing constitute 66% of all recorded packaging defects on the refill assembly line. Process stability analysis detects control limit breaches on specific production days due to operational parameters. Fishbone analysis traces defects to improper press temperatures, dirty sensors, and operator fatigue. Keywords Statistical Quality Control, Refill Packaging, Defect Reduction, Filling Assembly, Process Stability]]>
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