How DEHA’s SQA Protected Millions of Dollars in Production Costs for Clients

In a digital transformation project for a large-scale packaging manufacturing plant, a new system was designed to manage the entire bill of materials, from plastic films to printing inks.

During the design documentation analysis phase, DEHA’s SQA team identified that the material loss calculation formula was being developed based on a standard ERP model. In theory, this formula was entirely reasonable. However, in practice, each factory operates under unique conditions, and “standard” models are not always suitable.

Instead of accepting the finalized documentation, the QA team raised critical questions:

• How does the elasticity of plastic film change with environmental temperature?
• Does higher printing speed increase color overlap and ink consumption?
• When the factory operates at maximum capacity, do these variables remain consistent with the assumptions in the model?

These factors are often overlooked in conventional software systems but have a direct impact on real-world production. The SQA team conducted simulations based on specific operational scenarios of the factory. The results showed that:

If the original formula were applied, when operating at high capacity, the material consumption variance could reach 3–5%.

For a factory producing millions of units daily, this deviation is not just a technical figure but can lead to significant consequences such as:

• Substantial financial losses
• Inaccurate inventory reporting
• Disruptions in supply planning and production forecasting

After detailed analysis and discussions, the client decided to adjust approximately 70% of the calculation algorithms based on DEHA’s recommendations to accurately reflect the factory’s real operational conditions.

We do not share this story to claim that we discovered an error. We share it to help clients better understand the true value of SQA at DEHA.

SQA is not only about functional testing, bug detection, or ensuring that systems operate according to documentation. It is a process of questioning, validating, and challenging assumptions to ensure that systems accurately reflect real-world operations and business objectives.

In many cases, the greatest value of SQA lies not in fixing an existing issue, but in preventing potential risks before they become real losses.

We believe that trust in collaboration does not come from promises, but from the ability to ask the right questions, conduct in-depth analysis, and take responsibility for every detail within a system.

That is how DEHA approaches SQA. And that is how we protect our clients’ long-term interests.