How do you remove packaging without damaging the internal part?

[ALedesma01]

I need some help with a problem we are having with the technicians opening up the packaging and damaging the part inside by cutting or severing a wire harness that is assembled to the part, for example. I just began working for a semiconductor equipment manufacturer, 6 weeks ago, and after reviewing the discrepancy reports for the area I work in, realize a great percentage of the defects are caused by how the floor technicians open up the packaging. We recieve parts from the supplier which are vacuum packed and usually wrapped in foam within the vacuumed plastic bag. The techinicians will take a pair of scissors(used to be box cutters!) to cut through the plastic bag, but sometimes are aggressive with the scissors or will have them in a wrong angle which will cut or sometimes sever a harness, damage the paint, or cause some other physical damage to the part inside. Is there a cutting tool out there that is dull enough to not damage the part inside, but still sharp enough to cut through the plastic and foam packaging? I really don't want to write a work instruction specifically on "how to detrash a part". I feel that would tie us down, and we have enough work instructions already.

 

[RoxaneB]

There is the Skrapr , but I think the issue could also be associated with the process (method used) to open the packaging. Even you say that you don't want to write a work instruction on how to safely open up the packages, implying that you know the method is incorrect.

Why not simply developing a One-Point Lesson or visual Job Aid showing the correct way to position the packages and use the cutting tools. Have you simply reminded people of the proper method?

After all, these damages are costing money and people need to understand the consequences of their actions.

 

[Jen Kirley]

Welcome to the Cove!

Arghh! Today's "nuclear" packaging is a hassle! I have trouble opening the bag of cereal sometimes, without spraying the thing's contents. And my daughter has trouble with her grip, which makes it worse!

Is it always the same kind of packaging that gives you the trouble? Or is there a variety of types and associated problems? The worst, in my view is the vacuum packaging that adheres to itself all around the part.

How many of these types of packages get opened in a day or week?

 

[howste]

You can try this kind of letter opener:



They don't allow the blade to come in contact with the product. They may not work to open all kinds of packaging though.

 

[ALedesma01]

Thanks for the ideas, I will try to find a Skrapr to test on the floor, as well as the envelope opener, I have one at home I will bring to test. The number of items opened in a week is several, I don't have an exact number, but my best guess would be in the hundreds. I am in the middle of gathering pictures of damaged parts to present at the next meeting with the techs, and also to mention that care is needed in the detrash process.

 

[Jen Kirley]

I favor trying smaller, cheaper solutions first and moving toward more complex, more expensive solutions if needed. Try them yourself, and ask some techs to try them too. Involve them in the solution: in the process doing so you can describe the costs and associated problems of these damaged items. Ask their advice: work closely with them, or at least with those who are willing to work on the solution with you. In doing this I dare to hope your eventual solution will gain the credibility of having been originated, at least in part, within the people who "get it" - so much in behavior management is perspective.

If you can manage it, I further suggest returning to the group some kind of reward for this cost savings, even though it seems like people are just being gorillas. The message to send is that the organization notices their participation in problem solving and supports it. Changing behavior can be so challenging that I would not want to miss this chance to make a robust success out of it.

I hope this helps!

 

[Jen Kirley]

Thanks for the ideas, I will try to find a Skrapr to test on the floor, as well as the envelope opener, I have one at home I will bring to test. The number of items opened in a week is several, I don't have an exact number, but my best guess would be in the hundreds. I am in the middle of gathering pictures of damaged parts to present at the next meeting with the techs, and also to mention that care is needed in the detrash process.

I found something like it, I think.

 

[Al Dyer]

ALedesma01

Try a serrated plastic knife. ----------------- Seriously!!

Al...

 

[harry]

Looks like there is room for improvement - work with your supplier to improve it.

 

[somashekar]

Or, puncture and then peel rather than use scissors. I hope it does not matter if it tears in any direction.