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Checkweigh PCS Case Study

FMCG Production Line Operators use slow-mo video and our PCS tool to resolve a checkweigh issue and prevent line speed deceleration to help protect this FMCG's margins.

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A Food Manufacturing production team observed that a ‘checkweigh issue’ was resulting in correct weight product being rejected alongside underweight product – and increases in line speed exaggerated the problem.

The Problem

  • The production line packed product into individual cartons, passed them over checkweigh and metal detection machines before final collation into an outer carton.
  • The reject rate at the metal detection machine was high and once product had built up in front of the reject bin’s level sensor, the whole line would stop.
  • The operators would empty the reject bin, restart the line and immediately have to go back to empty the bin again.
  • The team believed that the problem had always been there but that it was now worse due to the recent increase in line speed.

There was talk of reducing the line speed to resolve the problem.

Find out how, with our help, the Operators used our PCS tool to determine the real root cause and is now boxing clever and faster than ever before to protect the company’s margins.

Download the PCS Case Study

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Over the past three months I have been concentrating mainly on changeover reduction, waste reduction and increased throughput. There has also been a challenge to behavioural patterns. All of these efforts have been using the knowledge that you gave me and I am delighted to say that all have been successful, culminating in increased throughput, less waste and an increase in OEE from an average of 78% to around 90%. There has also been a marked improvement with people issues.

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