Defective Product Screening Equipment
Equipment Overview
- Packs filled with shampoo are transferred in the X direction on a conveyor.
- The weight of the shampoo packs are measured by a weight checker when they are transferred onto the conveyor.
- If the weight is outside the allowable range, air cylinder Ⓐ stops the pack and air cylinder Ⓑ discharges it to the Y direction as a defective product.
Before Improvement
Defective products sometimes got past the rejection process due to the slow movement of air cylinder Ⓐ that was caused by fluctuation of the source air pressure.
➨ When the movement is too slow, an alarm activates and a choco-tei (a temporary stop) occurs.
Likewise, before Air cylinder Ⓑ discharged a defect, a new shampoo pack was often fed on the weight checker conveyor, which disabled a weight measurement.
➨ When the measurement failed, an alarm activated and choco-tei (a temporary stop) occurred. Also, some defective products did not fall in the defective product box, but fell out of the box.
Choco-tei (a temporary stop) due to Air cylinders Ⓐ and Ⓑ took place an average 3 times a day, each of which took 10 minutes of adjustments for recovery.
It took a total of 30 minutes per day for recovery from the choco-tei (temporary stop).
» 3 times x 10 minutes = 30 minutes/day
After Improvement
✪ Air cylinders Ⓐ and Ⓑ have been replaced by ELECYLINDERs.
✪ The result of the introduction of ELECYLINDERs is as follows:
Ⓐ Thanks to no speed fluctuations, defective products are not getting passed the rejection process.
The alarm no longer activates and choco-tei never occurs.
Ⓑ Because there are no speed fluctuations, another shampoo pack is no longer fed onto the weight checker conveyor before the proper time.
The alarm is not activated and choco-tei no longer occurs.
Defective products do not fall out of the reject box.
✪ No choco-tei occurs and no time is spent for recovery.
» Time for recovery: 0 minute / day
✪ Working hours has been reduced by 30 minutes per day.
Recovery time of 30 minutes per day from choco-tei has been eliminated.
✪ Annual saving for labor cost is US $1,400.
US$12 x 30 minutes (10 min. x 3 times) x 240 days = US$1,440.
*Exchange Rate: 1 (USD) = 100 (Japanese Yen).
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