Does Cpk analysis make sense on this study? Number of packaged parts per bundle

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Laura M

#12
So you can prove that with the gage extended, you ACTUALLY ship to the spec of 365, but because THEORETICALLY, you are shipping 3 extra pieces the bosses don't want to do it?

Not sure was a histogram will show as far as the number of pieces go, because you probably will be within 1 or 2 of the 365. A historgram of the actual thickness on several bundles that already are manually counted to 365 may help prove your point.
 

Al Rosen

Staff member
Super Moderator
#13
Wouldn't weighing be a faster way of verifying the proper amount than measuring the length of the stack or counting the no. of laminations. Could you weigh the stacks as part of your study? Even if your customer continues to count, you can weigh them. If this works, eventually your customer will come to trust your "count".
 
D

Dave Dunn

#14
I have to agree that selling the product by weight, or simply using a counting scale to weigh the bundles would be the best way to go. A counting scale can very accurately measure the correct quantity assuming the individual pieces are consistant in mass. Depending on how your process works, you could either adjust to the correct quantity before bundling the 300 pieces, or you could individually mark the accurate quantity on each bundle.

Look at it this way: they don't sell cereal based on how full the boxes are, they sell the cereal based on how many ounces or grams of product there is.

Most of our product is bulk packaged. We would not be able to assure our customers or ourselves of the quantity we deliver if we were not to use counting scales.
 
T

Totumfrog

#15
We also make motor laminations. We have found that the customer BOM on the motor has a specific number of laminations (say 365). However, there is a overall height required when those laminations are stacked in the motor. Due to material thickness variation, one motor may be 364 pcs., another motor may be 365 pcs. A challenge would be to find out what the overall height of the motor has to be and then gage your stack by overall height. My guess is your customer will complain if they are 1 pc. short but not 1 pc. too many.

With that being said, your Cpk analysis did not include any reference to material thickness. Your stack height will change based on thickness. Just a 0.05mm variation could result in 18.25 mm in overall height variation (365 x 0.05). Now I know that your material doesn't vary that much within a stack but it may from stack to stack. You need to calibrate your counting method (machine counter?) and measure overall variation of your material thickness.
 
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