At fruits and such, a local fruit concentrate manufacturer, frozen orange juice

Question

At fruits and such, a local fruit concentrate manufacturer, frozen orange juice is packed in 12-oz cardboard cans. These cans are formed on a machine by spinning them from preprinted cardboard stock and attaching two metal lids, one for the top and one for the bottom. After filling the container is carefully inspected. The inspector test how well the strip to open the can operates. If a strip breaks the can is considered non-conforming and unusable. Other packing non-conformities includes improper crimps holding the lids to the cardboard tube or poorly sealed lids. Fill rates are carefully checked to ensure that the containers truly contain 12-oz. Inspectors also check the cosmetics of the can. Incorrectly wrapped cans or crooked labels are considered non-conforming and unusable.

            An np chart for tracking unusable nonconformities needs to be established to track the level of nonconformities produced on a daily basis. The first 30 subgroups of size n=50 are founded on figure 1

Use the total number of defectives to create the np chart. How is the process currently performing? What is the process capability?

PART NO. OJ.1 GROUP: 1 Subgroup Time 07:00:00 07:16:00 Sample size Defective 12 15 STRIP BRK CRIMP WRAP BASE LABEL FILL Subgroup Time 08:20:00 08:36:00 Date 03/03/XX 03/03/XX Sample Size 50 Defective 16 STRIP BRK CRIMP WRAP BASE LABEL FILL Subgroup 11 12 Time 09:30:00 09:46:00 Date 03/03/XX 03/03/XX Sample Size Detective STRIP BRK CRIMP WRAP BASE LABEL FILL FIGURE 1 Defective Orange juice Cans MACHINE: Spinner VARIABLE: Seal 07:32:00 07:48:00 50 10 08:52:00 09.08:00 03/03/XX 03A03 XX 14 13 14 10:02:00 10:18:00 03/03/XX 0303/XX 17 12 08:04:00 10 09:24:00 3/03/XX 10 15 10:34:00 03/03/XX 22 11

Explanation / Answer

An investigation of the Pareto analysis reveals that the two largest problems are the fill level of the orange juice cans and the breakage of the plastic opening strip. Since the fill level appears to be the largest problem, the investigators decide to start their problem-solving efforts there.
Upon checking the operation, they determine that there is a serious lack of precision in filling the orange juice cans. The current method fills the can by timing the flow of the product into the can. This type of filling method does not account for the change in pressure in the level of the supply tank. With a full storage tank of orange juice there is more pressure in the lines, resulting in the overfilling of cans. As the volume in the orange juice storage tank decreases, the cans are underfilled.
Replacing the existing tanks and delivery system, retrofitting pressure meters onto the system, or installing a weight sensitive pad and fill monitor to the existing line are all suggestions for improving this process. An economic analysis reveals that the weight sensitive pad and fill monitoring equipment would be the most economical change. The can rests on the pad during the filling operation. When the can reaches a preset weight, the can is indexed to the next station. Previously, the can was indexed on the basis of time. This new method ensures that the volume in each can changes very little from can to can. The weighing device has been calibrated so that the variance in empty can weight and densitywill produce only a slight variation in the can fill volume.
The decision has been made to add the weight sensitive pad and fill monitoring equipment for a trial period.

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