Packaging Errors - quantity, missing components

[Jim 4E]

I'm looking for help in finding improved methods for 99+% accuracy in bulk packaging 'small' assemblies (roughly 2 inches in diameter and 2.5 inches long). We have been tracking our errors for quite some time, but have not found our way to reducing errors. The major issue is incorrect quantity, with the secondary error of missing components in 'kits'. I would appreciate any reommendations or leads to websites, etc.

[Jim Howe]

Originally Posted by Jim 4E

I'm looking for help in finding improved methods for 99+% accuracy in bulk packaging 'small' assemblies (roughly 2 inches in diameter and 2.5 inches long). We have been tracking our errors for quite some time, but have not found our way to reducing errors. The major issue is incorrect quantity, with the secondary error of missing components in 'kits'. I would appreciate any reommendations or leads to websites, etc.

I have seen "shadow boards" with a "vacuum-pac" work quite well. In fact almost idot proof. This application was used by a major manufacturer of x-ray and cat-scan equipment for their hospital installation kits. It was implemented shortly after they registrared to ISO 9001-1994. They photo printed the parts (including nuts and bolts) onto the cardboard backer. One photo for each part;i.e., if four bolts were needed, of a particluar size, then 4 photo's were put on the backer. These photo's were actually outlines of the parts. When fully implemented they never looked back problem was solved!

[D.Scott]

I am assuming you already use weigh counting for your bulk packaging. Is it possible your part is so light you might have to increase the "teaching" quantity to get a more accurate piece weight?

Dave

[Ernst Kong]

Originally Posted by Jim 4E

I'm looking for help in finding improved methods for 99+% accuracy in bulk packaging 'small' assemblies (roughly 2 inches in diameter and 2.5 inches long).

1] high resolution weight counter - cheap, sensitive to in door air flow ;

2] auto feeder + sensor/counter - expensive, tailor made for each parts , high precision (0 descrepancy til date in my experience).

[Wes Bucey]

Originally Posted by Jim 4E

I'm looking for help in finding improved methods for 99+% accuracy in bulk packaging 'small' assemblies (roughly 2 inches in diameter and 2.5 inches long). We have been tracking our errors for quite some time, but have not found our way to reducing errors. The major issue is incorrect quantity, with the secondary error of missing components in 'kits'. I would appreciate any reommendations or leads to websites, etc.

This is essentially an exercise in "mistake proofing." You might gain some insight into the process of mistake proofing by browsing this site:
http://www.campbell.berry.edu/facult...pokayoke.shtml
Jim Howe has described one form of mistake proofing. When you become familiar with the process of mistake proofing, you may be able to create one of your own.

Personally, I would not put much stock in trying to automate a process such as you describe unless you were doing more than 10,000 packages per shift. Automation considerations always come down to the economics of price per package when you compare

• the cost of amortizing capital equipment and future changes to equipment to accommodate changes in product
  AGAINST
• the cost of providing a "mistake proof" process for humans.

[IEGeek]

We also had high shipping errors (low DPMs - but that is in another post) but high shipping errors. Quantity issues, wrong parts in the box etc. I used to receive approx. 3 - 5 complaints a day. One thing I implemented was a shipping inspection. Our lead inspector has to visually check all boxes going outthe back door. She is checking quantity and part content. After she has verified the contents she affixes a little sticker to the box. The sticker is bright green and states, "Inspected with Pride by Lupe." She also stamps the Sales Order as verified. This has reduced two problems. One - now our customers know we are checking every box and are more apt to "trust" us (issues from the past, do not ask!!) Two, we have traceability when there is an issue. We now have less than 1 shipping error per week.

The stickers have caught on as well. We now have "Packed with Pride by XXX"
"Manufactured with Pride by XXX" Actually now that I think about it our boxes of product look like a VW van from the 70's with all the bumper stickers (not really)

We were in a high automation phase awhile back. The payback is just not there in our facility. In fact our old GM is no longer here, due to the fact that he purchased several hundred thousand dollars worth of automated equipment and received very little or no payback. They are nice and sexy to look at, however they are not achieving our goals, so it makes it harder for us to get the stuff we now need. For a good example of automation that worked there are several comapnies out there that have made it work after years of research, and process improvement. Nintendo in Seattle is one (ASQ conference ) I recommend the tour if you are going.

Just some thoughts....

[David Hartman]

Originally Posted by Jim 4E

I'm looking for help in finding improved methods for 99+% accuracy in bulk packaging 'small' assemblies (roughly 2 inches in diameter and 2.5 inches long). We have been tracking our errors for quite some time, but have not found our way to reducing errors. The major issue is incorrect quantity, with the secondary error of missing components in 'kits'. I would appreciate any reommendations or leads to websites, etc.

Jim,

I know that you have stated that you have been "tracking" your errors, but to what degree have you performed root cause analysis (and be careful here that you're not looking for cause of each incident versus cause of the systemic problem)?

[RMedrano]

We are having similar problems at our facility, and was wondering what people may have done to correct them.

Basically we have two frequent types of complaints, One is that we ship a container of parts that contains two different part numbers. Usually the bottom layer of the container has the wrong part, so even doing a top layer inspection would miss it.

The other complaint is just a container of parts that is mislabled. For one particular customer we make two different parts, both get packed in containers that are almost identical. basically what happens if that the containers are mislabled. This is something that a Top layer inspection would solve but my boss is looking for some sort of electronic system using scanners to track inventory and partials.

Right now we do have a computerized labeling system, but the labels are only put on finished containers. If a set up or change over is done before a container is finished, other than a "partial layer" tag there is no indication of what part is actually in the box.

Anyone have any Ideas?