Case study 


27% rejects stopping all days a 

Beverage Bottling Line


 The rejects' accumulation table of an Electronic Inspector in a Beverage Bottling Line, as it appeared to the eyes of the Operators and Management along 6 consecutive months after the day of the Line startup. A daily spectacle during the initial ~15000 bottles of each one new batch of production, with average rejects ~27 % and Line forcedly stopped by the amount of rejects.  Those who had the responsibility for the rejecting device sentenced that what visible on left side ...are not False Rejects by the Electronic Inspector.  Say, they were caused by something external to the Inspector.  5 months after the telenovela started, banally changing the staff intervening in that machine solved in a matter of minutes the problem.  Root Cause of it all: erroneous previous setup of the Electronic Inspector.  Nothing more than what the Bottler suspected since the telenovela started to be staged















 

The rejects' accumulation table of an Electronic Inspector in a Beverage Bottling Line, as it appeared to the eyes of the Operators and Management along 6 consecutive months after the day of the Line startup. A daily spectacle during the initial ~15000 bottles of each one new batch of production, with average rejects ~27 % and Line forcedly stopped by the amount of rejects.  Five alleged “experts” from two countries sentenced that what visible in the figure above above are not False Rejects by the Electronic Inspector.  Say, they had a cause lying out of the Electronic Inspector.  Also, the same five “experts” were sure about the cause: a few drops of water existing out of the plastic bottles were causing such a daily mess.    5 months after the telenovela started to be staged, banally changing the Vendor’s Staff on-site solved in a matter of minutes the entire problem.   To root cause analyse the situation really requested minutes and the new diagnosis passed to: erroneous previous setup of the Electronic Inspector.   Exactly what the Bottler suspected since the start.  In the special case here considered, the Root Cause is human-factor, say the missing basic skills and/or capabilities and/or training of the staff involved in this Project



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