Manual vs. Automated Statistical Process Control in the Food Industries

Israel Ortega-Ramos The Prime Example Our sassy-made visit to a food furtherance imbed in New jersey highlighted the inconsistent settlements of statistical put to work check out routinely faced by feel assert Managers. mathematical product weight readings were interpreted from the manuf turn of eventsuring floor, entered into an Excel spreadsheet and analyzed. The results produced no predictable to a lower mark or over weft trim back despite the fact that the comparable lot used the aforementioned(prenominal) scales at the same term of day. The problem is simple and unplumbed. pitying fallacy is an inevitable wear out of the action of collecting statistical selective information.This is consistently unmarked in companies that use manual SPC1 (statistical process function) for their manufactured goods. To ensure the valet error divisor is drop deadd, resulting in lower be and increased profitability, manufactures must receive utilizing much than high- tech manner of collecting, analyzing, and storing SPC selective information. The Hidden Problems of the rate of flow Manual SPC Process To better actualise the core problem, and find a solution, it is important to under(a)stand how this food packaging plant utilizes manual SPC.Generally, several renders be taken from a product line at different times of day, usually 15 or 20 samples at a time. These samples are then individually weighed a line player records the results on a clipboard for analysis. The individual weight readings are entered into a computer and various statistical calculations are derived from the deliberateness results, including frequency distribution charts and Pareto charts that are used to adjust the actual modify motorcars to deliver a consistent result.The choice Manager must then decompose whatever conflict between under filling a software program, which breaks government laws and overfilling a package which causes lost revenue. Using the p lat to get a better rationality of SPC leave alone make it easier to locate the fundamental problems with the manual SPC brass in use. The problems begin with the manual recording of 15 selfsame(a) products by the line workers. The simple act of weighing an item then transferring the result to a clipboard by pencil or pen is flawed and full of manageable errors, i. . the incorrect number can be save or a sample can be weighed accidentally much than once. This means the human emotion factor begins to play a large part in the problematic result. In addition, the four-in-hand obtains the clipboard results from the same worker who is required to full inside the hot filling machine to adjust the volume if the weight results are not consistent. A line worker therefore might also usurp that weight readings on the clipboard that differ from severally other might mean he/she is not doing a good job.The implicit in(p) result of a manual SPC system is the company loses money resul ting when each package of food is either overfilled beyond the nominated weight or worse creation under-filled which could mean hefty government fines. To summarize, the veritable manual SPC process allows too many another(prenominal) errors and offers no tieability of weighing results throughout the system. The execution of an automated SPC scale system would eliminate these manual user errors with only a few changes and a small large(p) investment. The Advantages of an Automated SPC SystemDesigning an automatic SPC system that eliminates human error begins by removing the manual section from employee responsibility. This pull up stakes alleviate human recording errors and the fudging of actual weight results. To accomplish this, the antiquated scale, clipboard, and pencil must be withdraw and re hardened with a scale system outfit with automated SPC software. This software is full configurable to recompense all SPC tolerances. The scale display pass on actually promp t the worker when to place a product on the scale.The fully automated SPC weighing machine System depart not allow products lay on the scale to be removed kinda only permit the addition of new products. This will eliminate the possibility of placing the same product on the scale more than once, as well as any confusion and/or fudging. The scale will then calculate the statistical data after the last product is placed on the scale and store this data in a password-protected memory for hookup by the Quality Manager. This statistical data can then be direct wirelessly to a spreadsheet, printed on a trail to accompany the sampled roduct, or simply viewed on the scale interface. The flow diagram down the stairs shows the alterd SPC process. Companies can also utilize various affiliateivity and software options that can commix filling machines to automated SPC scale systems. This means that fill volumes based on trends metric by the scale can be adjusted via an automated sys tem. Quality Control Managers and Plant Managers can also connect all the SPC scale systems in a factory via a central control computer that will provide comfy access to real-time data.Integrating an automated SPC Scale System into a manufacturing environment will contrive the following advantages over the honest-to-goodness manual SPC systems Upgrading outdated manual SPC processes is the freshman step to improve overall quality, efficiency, and trace ability. This can be accomplished with as little as $5,000 in cap investment. Quality Control Managers and Plant managers have to take a hard whole step at how their product samples are creation weighed and how these measurements are turned into results that can improve production line efficiency.It is now time for companies to step into the 21st century and boost to a fully automatic SPC weighing system. pic Error Filled SPC System digress Statistical data evaluated and translated into adjustments to correct filling machin e fill volumes. Data transferred from clipboard to spreadsheet for statistical evaluation. Each product is placed on scale. Random Batch of Product taken from Production Line.Filling machines manually adjusted tally to collected data. Data collected by Quality Control Manager. Weight is recorded on clipboard in order weighed on scale. coating Optional Filling Machines adjusted automatically by SPC scale system. FINISH Random Batch of Product taken from Production Line. Each product is placed on scale. Scale automatically calculates statistical data. Statistical Data transferred to computer database directly via wireless or Ethernet connection. START Product Weight Scatter Graph.