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Gary E MacLean
Good morning all;
I would like to request some assistance.
We bottle fruit into glass jars with metal closures. They rapidly flow down the filling line at the rate of about 15,000 jars per hour. We have an in-line metal detector that scans every jar prior to having the metal cap put on. We verify the detector with known rejects once every one hour.
Typically we can expect about 5 legitimate rejects per month or about 5 jars every 2.5 million jars. On occassion the metal detector vibrates out of setting. We can fix that, that is not the problem. But, when we go to check our known rejects they fail. By the time we check we have produced 15,000 jars with closed lids and vacuum established.
We segregate all materials then try to figure out what to do. Our FMEA, or scheduled process, says we must rerun all product. That is we must open every jar, tossd the lid, dump the fruit into a hopper for refill and either wash or trash the jars.
What I am hoping is that there is a statistical method for evaluating, sampling the suspect material to make a viable risk analysis and resultant decision that may save the rework and material loss costs.
Can anyone help?
Rate = 15,000 / hour
Fail = 5 / 2,500,000
Check = 100%
Thank you
Gary E MacLean
I would like to request some assistance.
We bottle fruit into glass jars with metal closures. They rapidly flow down the filling line at the rate of about 15,000 jars per hour. We have an in-line metal detector that scans every jar prior to having the metal cap put on. We verify the detector with known rejects once every one hour.
Typically we can expect about 5 legitimate rejects per month or about 5 jars every 2.5 million jars. On occassion the metal detector vibrates out of setting. We can fix that, that is not the problem. But, when we go to check our known rejects they fail. By the time we check we have produced 15,000 jars with closed lids and vacuum established.
We segregate all materials then try to figure out what to do. Our FMEA, or scheduled process, says we must rerun all product. That is we must open every jar, tossd the lid, dump the fruit into a hopper for refill and either wash or trash the jars.
What I am hoping is that there is a statistical method for evaluating, sampling the suspect material to make a viable risk analysis and resultant decision that may save the rework and material loss costs.
Can anyone help?
Rate = 15,000 / hour
Fail = 5 / 2,500,000
Check = 100%
Thank you
Gary E MacLean