This study aims at a set of quality issues recurring in a leading third-party logistics provider in Saudi Arabia, where products often arrive damaged in sealed cartons. Such incidents denote inefficiencies in handling, packaging, and inventory management that raise operational costs, curb customer satisfaction, and might even result in a breach of trade law. A comprehensive assessment of the damage and reduction thereof employ Lean Six Sigma principles through the DMAIC framework, aided by Failure Mode and Effects Analysis (FMEA). DMAIC goes about defining the damage problem, establishing baseline measures for quantifying the damage, determining the root causes of the damage, and contriving improvements to suit each cause accompanied by controls for sustainability. FMEA assessment of potential failure modes in handling and storage operations calculates the Risk Priority Number (RPN) for each and addresses those modes evidencing the highest risk levels first. Adopting this integrated approach shall considerably reduce the destruction of cartons by improving packaging standards and handling procedures. Secondary problems such as incorrect labeling and short shipment also become addressed under improved process visibility and compliance monitoring. The findings show how the lean six sigma methods, combined with risk-based prioritization, build a solid quality-assurance system geared towards logistics operations. This case contributes to practice and literature by extending the applications of Lean Six Sigma and FMEA evaluation to the Middle Eastern logistics context to support Saudi Vision 2030 for operational excellence and supply chain resilience.

Keywords

Lean Six Sigma, DMAIC, FMEA, Logistics Quality, Saudi Vision 2030