Big problems with Inspection - Manual Operation - Needs experts

T

TheRiddle

#1
Hello all!
how's your day?

I'm working for lollipops Industry as quality control leader..
my team in packaging department have a problem with inspection
1- we package lollipop in cans with 50 lollipops manually (problem in the count), sometimes it may be 47 lollipop in the can, sometimes It 55, sometimes 45
2- visual inspection (problem in defects)
so we have a lot of defects 1% defects in the box
we have 100% inspection but we still have defects .. It's so hard to turn our process to be automatic packaging .. by the way we produce more than 5000 cans per day

so how can we pass the problem of the manually counter of lollipop?
and how can we pass the lollipop defects in the cans?
 
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G

Gert Sorensen

#2
Re: Big problems with Inspection needs experts

Hi, and welcome to the Cove.

I can't tell you about the defects, but perhaps you can elaborate a bit about the kind of defects? That may help you to get more qualified answers.

Regarding the count, the easiest way to address that would be to weigh the boxes. You should be able to establish a limit that is easy to verify.
 
A

Alexisss

#3
Re: Big problems with Inspection needs experts

Hello all!
how's your day?

I'm working for lollipops Industry as quality control leader..
my team in packaging department have a problem with inspection
1- we package lollipop in cans with 50 lollipops manually (problem in the count), sometimes it may be 47 lollipop in the can, sometimes It 55, sometimes 45
2- visual inspection (problem in defects)
so we have a lot of defects 1% defects in the box
we have 100% inspection but we still have defects .. It's so hard to turn our process to be automatic packaging .. by the way we produce more than 5000 cans per day

so how can we pass the problem of the manually counter of lollipop?
and how can we pass the lollipop defects in the cans?
Hi!
for the packaging problem, use scale and weigh the box with the contents!
for the defects, can you give us a couple of examples? are there defects at the cans or the lollipops? When you say 1% defects in the box, you mean 1% of the boxes are defective? Cause if you got 1% defects in the box and the box has 50 pcs, then you got 0.5 defects per box, which doesnt sound ok...
thanks
 

qusys

Trusted Information Resource
#4
Hello all!
how's your day?

I'm working for lollipops Industry as quality control leader..
my team in packaging department have a problem with inspection
1- we package lollipop in cans with 50 lollipops manually (problem in the count), sometimes it may be 47 lollipop in the can, sometimes It 55, sometimes 45
2- visual inspection (problem in defects)
so we have a lot of defects 1% defects in the box
we have 100% inspection but we still have defects .. It's so hard to turn our process to be automatic packaging .. by the way we produce more than 5000 cans per day

so how can we pass the problem of the manually counter of lollipop?
and how can we pass the lollipop defects in the cans?
For the question 1, I agree with the other covers.
In any case it seems strange that you cannot find an automatic solution to package the product. Is it an organization choice or did you have already try automatic solution that did not satisfy you?:bigwave:
 
T

TheRiddle

#5
Hi, and welcome to the Cove.

I can't tell you about the defects, but perhaps you can elaborate a bit about the kind of defects? That may help you to get more qualified answers.

Regarding the count, the easiest way to address that would be to weigh the boxes. You should be able to establish a limit that is easy to verify.
thank you for your attention and replay
I have a lollipop defects I know the root cause but we cant solve the root cause because it will be expensive, because we have old machines and we need to change it and I will attach a pic of our defects .. so my problem is how to not deliver the defects to our customer
we are already weighing the boxes but we still have the problems
by the way one of our critical problem is the empty wrapping which the customer in the boxes and they think that we are cheating them

Hi!
for the packaging problem, use scale and weigh the box with the contents!
for the defects, can you give us a couple of examples? are there defects at the cans or the lollipops? When you say 1% defects in the box, you mean 1% of the boxes are defective? Cause if you got 1% defects in the box and the box has 50 pcs, then you got 0.5 defects per box, which doesnt sound ok...
thanks
thank you Alexissss
we are already weighing the boxes but we still have problem in the count
and the defects in the lollipop.. we have 1% of the boxes contain lollipop defects
 
T

TheRiddle

#6
For the question 1, I agree with the other covers.
In any case it seems strange that you cannot find an automatic solution to package the product. Is it an organization choice or did you have already try automatic solution that did not satisfy you?:bigwave:
the company can't use automatic solutions because we don't have the facilities and the money to build new automatic system. I'm suffering with that but i have to think positive
 

qusys

Trusted Information Resource
#7
the company can't use automatic solutions because we don't have the facilities and the money to build new automatic system. I'm suffering with that but i have to think positive

Undestood.
As to the wrong number of lollypops in the cans, I think that you could adopt a solution to modify the can, given that you are in cost reduction to rquest capitals to buy automatic equipment for packaging.
You could insert in inside the can a sort of a "coin" with holes, so that you can insert the lollupops inside this hole. In a can you can put two/three layers and have the right quantity inside each one.
This method could be considered a sort of "poka yoke", because the operator immediately check if a "hole" is missing of the related lollypop. :bigwave:
 
H

Hodgepodge

#8
we are already weighing the boxes but we still have the problems
by the way one of our critical problem is the empty wrapping which the customer in the boxes and they think that we are cheating them
Two possible solutions here:
1) Weigh the lollipops, then put them in the box. The difference in the weight of the boxes and or "empty wrapping" could be misleading.
2) Use a scale that measures to a greater accuracy.
 
T

True Position

#9
If the piece price is low enough it may be cheaper to just write 50 on the box and set your counting scale and automated counting system to 52 or 53 pieces. Most of your customers get slightly more then they ordered, some get just what they ordered and a couple get significantly more.

While your lolipop cost is higher you save significantly on inspection and customer complaints. I know bolt suppliers who do similar.
 
T

TheRiddle

#10
Undestood.
As to the wrong number of lollypops in the cans, I think that you could adopt a solution to modify the can, given that you are in cost reduction to rquest capitals to buy automatic equipment for packaging.
You could insert in inside the can a sort of a "coin" with holes, so that you can insert the lollupops inside this hole. In a can you can put two/three layers and have the right quantity inside each one.
This method could be considered a sort of "poka yoke", because the operator immediately check if a "hole" is missing of the related lollypop. :bigwave:
thank you for your attention
our lollipop is looklike balls what about a sheet of paper between groups of lollipop each group have 10 lollipops ????.. I will try to do that

Two possible solutions here:
1) Weigh the lollipops, then put them in the box. The difference in the weight of the boxes and or "empty wrapping" could be misleading.
2) Use a scale that measures to a greater accuracy.
can you tell me more information about the scale?

If the piece price is low enough it may be cheaper to just write 50 on the box and set your counting scale and automated counting system to 52 or 53 pieces. Most of your customers get slightly more then they ordered, some get just what they ordered and a couple get significantly more.

While your lolipop cost is higher you save significantly on inspection and customer complaints. I know bolt suppliers who do similar.
thank you for your support:) but the problem is that our lollipops are expensive :(
 
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