抄録
According to high competitive business, the production of high quality products at the lowest cost becomes business strategy. In this case study of a dish-washing liquid packaging process, the overweight and underweight fillings lead to the extra production costs in terms of raw materials consumed, give-away, rework, especially less customer confidence in the product. The production data indicated that 50 tons/month of the consumer products, mainly dish-washing liquid of about 40 tons, lost which cost 10,000 US$/month. Thus, the efficient control of product weight in the packaging process is significantly required. In this work, the QC tools (the Pareto Diagram, Cause and Effect Diagram) were applied. The Design of Experiments (DOE) by the Minitab Program and Why-Why Analysis were used to pinpoint the significant parameters of the weight deviation of dish-washing liquid during the packaging. Typically, controlling of weight deviation of dish-washing liquid by adjusting a few milliliters of the filling volume is difficult. Most dish-washing liquid manufacturers are looking for high accuracy scaling system, however, the constraint concerns its high cost. Based on the statistical analysis of product weight in this dish-washing liquid packaging process, it was found that the weight deviation from the target value was high. The highest standard deviation of the product weight was 2.36. Moreover, averagely within 8- hour operating time there were 2,000 bottles on the pulled off-line after filling up. After preliminary modifications of the existing gravity filling machine and load cells, weight deviation of dish-washing liquid decreased resulting in cost saving. The detailed results and the improvements were achieved and stated inside.
