Big problems with Inspection - Manual Operation - Needs experts

[TheRiddle]

You shall do a research because there are many companies that provides ad hoc solution.
However, I did not understand.
I thought you had the problem of counting of the lollipops to put in the envelop.
My idea went in that sense.

this is the can that I have problem with
DEAD LINK TO A GRAPHIC REMOVED

 

[somashekar]

this is the can that I have problem with
DEAD LINK TO A GRAPHIC REMOVED

I guess you have resource of manual labor to assign and train to the packaging section and provide them simple tools and solutions.
My Suggestion:
Get some simple trays made which have 10 cavities that can hold 5 units each and this 5# can be easily and visually seen and counted. Let a counting person place 5 units in each of the 10 cavity of a tray and check same time the count and place 1 extra in the middle of the OK tray.
The packer person will pack all contents when he sees the centre unit in the tray and return empty tray back to the counting person. This way each pack will have atleast 50 or 51 units (your counting problem solved) and the trays can be reused over and over again.
See how it can work for you and how your people will appreciate the ease and method and adopt it with simple training.
By the way can you explain your counting of 50 units and the can packing process steps.

 

[TheRiddle]

I guess you have resource of manual labor to assign and train to the packaging section and provide them simple tools and solutions.
My Suggestion:
Get some simple trays made which have 10 cavities that can hold 5 units each and this 5# can be easily and visually seen and counted. Let a counting person place 5 units in each of the 10 cavity of a tray and check same time the count and place 1 extra in the middle of the OK tray.
The packer person will pack all contents when he sees the centre unit in the tray and return empty tray back to the counting person. This way each pack will have atleast 50 or 51 units (your counting problem solved) and the trays can be reused over and over again.
See how it can work for you and how your people will appreciate the ease and method and adopt it with simple training.
By the way can you explain your counting of 50 units and the can packing process steps.

Great Idea but i think it may be increase the cycle time of production
the count operator is already collecting 5 lollipop and put it in the can without the trays making 50 but we don't have the accurcy with counting

 

[somashekar]

Great Idea but i think it may be increase the cycle time of production
the count operator is already collecting 5 lollipop and put it in the can without the trays making 50 but we don't have the accurcy with counting

Oooooh OK, but you and me do not know if he is putting 9 times or 11 times making it 45 or 55 ?
About the cycle time, it can only be commented after application and running rather than upfront. Perhaps a simple line balancing is necessary to get the desired volumes run.
I believe counting tasks must not be left to memory of the operator and it must be system built, as well as visible for online supervision.
I also believe that when manual tasks give repeated problems it is good to split the task where one can exercise simple check and correction on the other.

 

[TheRiddle]

Oooooh OK, but you and me do not know if he is putting 9 times or 11 times making it 45 or 55 ?
About the cycle time, it can only be commented after application and running rather than upfront. Perhaps a simple line balancing is necessary to get the desired volumes run.
I believe counting tasks must not be left to memory of the operator and it must be system built, as well as visible for online supervision.
I also believe that when manual tasks give repeated problems it is good to split the task where one can exercise simple check and correction on the other.

agreed
I will try to implement that Idea

 

[The Specialist]

TheRiddle;

Despite your production-line problems, which I know you are most interested in ‘fixing’…

Can I ask; How are the final packaged products managing to get to the customer?

Are you conducting check-weigh of 100% of packaged product or just a sample?


Are you re-working those products which do not meet weight specifications?

 

[TheRiddle]

TheRiddle;

Despite your production-line problems, which I know you are most interested in ‘fixing’…

Specialist thank you for your interest
yes there is production-line problems and it's critical problems .. and these problems are the root causes for alot of problems .. it's manual lines and the human mistakes around 40% of these problems .. the managers way here to solve the problems is salary deduction so they are suffering from these problem since the company has been built and they couldn't prevent these problems . I'm newer for this company and the owner asks me to decrease the customer complaint first and there is no facilities in this time to prevent the root causes

Can I ask; How are the final packaged products managing to get to the customer?
Are you conducting check-weigh of 100% of packaged product or just a sample?

there is alot of operators and supervisor and inspector which they produce a thousands of lollipop cans .. we weigh 100% of these cans but we still have the problems with the count

Are you re-working those products which do not meet weight specifications?

yes we are

 

[msbettyhunt]

There is a machine that helps in counting problems while packaging at pdimachinery (bulk-case-pack-by-count). I can't share here the links as per security reasons.