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Big problems with Inspection - Manual Operation - Needs experts

H

Hodgepodge

#11
can you tell me more information about the scale?
Assumption: The manufacturing methods you use produces homogeneous units.

If the weight of each lollipop is uniform, then weighing them is a good idea. Let’s say one lollipop weighs .03 kilograms. If your scale accuracy is .05 kilograms (or higher) your process is likely to be way out of control, as in your description. A scale with an accuracy of 4 times greater (I’m sure some will say 10 x) than the weight of the item you are measuring would be more appropriate.

Such a scale can be used to better determine how much the weight varies from pop to pop, providing you with the proper range of weight to use as the weight requirement needed to equal 50 lollipops.
 
#12
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
Are lollipos the same called "chupa chupa" , with ball and a stick?

To do this change, pls involve also the operatos of the line through suggestions system. Some good idead could come out.
As to your solution, try it. My suggestion went towards an easier visible control, but clearly you shall also face the costs of a change.:bigwave:
 
T

The Specialist

#13
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?

OK… Before reaming off a load of advice and potential solutions I am going to make a load of assumptions about your process, which I would like you to correct, where necessary, so that I get a picture of your operations…

This is what I imagine…(an entirely manual inspection and packing process):

Lollipops are manufactured and visually inspected for quality whist being conveyed to a ‘wrapping’ machine, which individually wraps each lollypop?

The wrapped lollypops are further conveyed, in a continuous line, where packaging staff ‘pick and place’ lollypops into a can/box. The packaging staff counts the lollypops into the container?

The container is sealed by another process and check-weighed at the end of the line before tertiary packaging takes place?

You have no other inspection systems in-line, beyond (human) visual inspection and final check-weigh?

You have a unit quantity target for the day, which you must meet? As a result of this the machinery and packaging staff must operate at a designated speed.


I am merely trying to clarify your situation, as it sounds as though there are time and personnel considerations at play here, as well as the check-weigh issues that others have highlighted.

With greater clarification of the whole process, we will be able to give more complete advice.
 
T

TheRiddle

#14
Assumption: The manufacturing methods you use produces homogeneous units.

If the weight of each lollipop is uniform, then weighing them is a good idea. Let’s say one lollipop weighs .03 kilograms. If your scale accuracy is .05 kilograms (or higher) your process is likely to be way out of control, as in your description. A scale with an accuracy of 4 times greater (I’m sure some will say 10 x) than the weight of the item you are measuring would be more appropriate.

Such a scale can be used to better determine how much the weight varies from pop to pop, providing you with the proper range of weight to use as the weight requirement needed to equal 50 lollipops.

the weight of lollipops is not uniform the target weight is 13.5 gm and the AQL 0.3 gm so 13.2 is aceppted and 13.8 is accepted but the actual variation is 5 gm :( and this is one of my team problems . I have analyzed the route cause by fishbone with the team but we didn't reach the route cause they are not professional enough and i'm newer in the food industry but when i used histogram i have found that the problem came from the roller that roll the lollipop material into the former and i'm trying to solve this problem. we already weigh the lollipop after packaging but this is not accurate enough because we still have the problem.. but now i want to try to prevent the count mistake as much as possible before continouse improving


Are lollipos the same called "chupa chupa" , with ball and a stick?

To do this change, pls involve also the operatos of the line through suggestions system. Some good idead could come out.
As to your solution, try it. My suggestion went towards an easier visible control, but clearly you shall also face the costs of a change.:bigwave:

it's looks like chupa chupa but ours are called sima lika
and thank you for your suggestion and i will wait more of suggestions


OK… Before reaming off a load of advice and potential solutions I am going to make a load of assumptions about your process, which I would like you to correct, where necessary, so that I get a picture of your operations…

This is what I imagine…(an entirely manual inspection and packing process):

Lollipops are manufactured and visually inspected for quality whist being conveyed to a ‘wrapping’ machine, which individually wraps each lollypop?

yes .. visual quality ( defects and weights)

The wrapped lollypops are further conveyed, in a continuous line, where packaging staff ‘pick and place’ lollypops into a can/box. The packaging staff counts the lollypops into the container?

yes .. exactly

The container is sealed by another process and check-weighed at the end of the line before tertiary packaging takes place?

all these processes are happened in one process

You have no other inspection systems in-line, beyond (human) visual inspection and final check-weigh?

Just human visual inspection in the production, after wrapping and after packaging, and there is one inspector in the final store and we still have problems with customers :D because we have bad quality system

You have a unit quantity target for the day, which you must meet? As a result of this the machinery and packaging staff must operate at a designated speed.

more than 30 ton every month.. the company interested in production more than quality


I am merely trying to clarify your situation, as it sounds as though there are time and personnel considerations at play here, as well as the check-weigh issues that others have highlighted.



With greater clarification of the whole process, we will be able to give more complete advice.
i'm waiting your advices .. I want to change my company culture because there is a wronge culture in the company
 
#18
no it's not.. this is the lollipops that we produce I think it's hard to make a box that can accomodate correctly 50 lollipop

Hi Riddle,
I know that there areoptical sensors that count items.
I remember this from my previous industrial engineering . They are available on the market, you shall only to set where they shall be applied in the line . They transmits the counting in real time on the monitor and the operators can visualize. In case of an error ( more items in the envelope) you can adjust the number of lollipos.
I do not know if this techinical solution is valid for yuo based upon cost reduction. However these sensor are not so expensive as well the related maintenance and installation. This application is very common in the food industry and it based upon the theory of the automatic control.
What about?
PS:
I have seen that the packaging is done inside plastic envelope and not in cans.:bigwave:
 
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T

TheRiddle

#19
Hi Riddle,
I know that there areoptical sensors that count items.
I remember this from my previous industrial engineering . They are available on the market, you shall only to set where they shall be applied in the line . They transmits the counting in real time on the monitor and the operators can visualize. In case of an error ( more items in the envelope) you can adjust the number of lollipos.
I do not know if this techinical solution is valid for yuo based upon cost reduction. However these sensor are not so expensive as well the related maintenance and installation. This application is very common in the food industry and it based upon the theory of the automatic control.
What about?
PS:
:bigwave:

this is good Idea but do you think that it would be useful in manual packaging in cans? .. do you know what's the name of this optical sensore?


I have seen that the packaging is done inside plastic envelope and not in cans.

I just showed him the shape of lollipop we packging the lollipop in cans and inside plastic envelope and my problem with the cans

thank you:agree:
 
#20
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.
 
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