This thesis is about improvement of Head Stack Assembly packaging that is the major component in Hard Drive. The purpose of thesis is to provide the new packaging design and concept that reduces freight cost and packaging cost. The author had decided to use Six-Sigma methodology in packaging development process and tried to fulfil all customer requirements with Quality Function Deployment flow. The study was started with searching for an appropriate quality improvement process that can be applied to solve the packaging problem in both macro and micro level. The factors that were related to the problem had been prioritized. And the factors that have most impact to objective will be selected for analyse and improve. The new concept packaging from the research had been totally changed from the original design that was designed for group packaging to be the transport packaging. The new concept packaging had been tested and evaluated by using statistical analysis. New packaging is also implemented as the pilot run to assess the negative impact to the quality that may be occurred from packaging cost reduction. The success from this project can help company reduces the packaging cost per HAS from 0.598 US dollars to 0.156 US dollars. Moreover, the new packaging also reduces freight cost per HAS from 0.582 US dollars to be only 0.205 US dollar. During packaging development process, the author also applied force field analysis to build up the co-operation in packaging improvement form management level and shop floor worker level at the same time. After the research, the main purpose of HAS packaging has been changed from group packaging for sales to be packaging for transportation between factories instead. The outcome from research have been summarized and documented to be the reference for packaging improvement in the future.