Root Cause Analysis. Case Studies. The Gold-made electronic cards

Case History

Gold-made electronic cards

Imagine two huge cases arrived to your store today, filled with the spare parts you ordered and waited for 4-6 months. Electronic cards and other parts urgently needed to let your Machinery produce in Quality and Safety.

Now add that: “nothing functions”.

Well, not exactly nothing, rather only 5 %. Checking one-by-one all of the cards in those pallets, a Team of four different electronic technicians discover that 95 % of the items are defective. Used cards, cleaned, repainted with transparent lack and resealed in new plastic bags to look-like a new.

Who knows, maybe it’s a mistake and used replacement cards have been exchanged for new….?

But, add that the cards into these two anomalous pallets have been billed to the Food and Beverage Company for a unitary amount of dollars nearly three times the new cards always acquired.

What do you imagine could be the most reasonable Root Cause for these discoveries ?

Gold-made cards. Imagine two huge wood crates arrived to your store today, filled with the spare parts you ordered. Electronic cards urgently needed in your Machinery. Now add that it is soon discovered that “nothing functions”. Checking one-by-one all cards it is discovered that 95 % of the items are defective, used cards, cleaned and resealed to look-like a new…..

Links to other Case Studies:

In-the Machine inspectors reduced to Standalone. Introduction

“Actions to hide the never commissioned synchronisation of Inspector, Labeller and Conveyor, also implying a permanent impossibility for the Bottler to fulfill the triadic quest for:

minimum losses,
minimum downtimes,
maximum rejection of defects and safety”

“...service technicians’ skills are part of the final added-value of the Electronic Inspector, because they are those one who shape the future years of the equipment.

World’s most expensive and higher Quality Electronic Inspector, left in the hands of some of the worst technicians, always perform much worse than World’s cheaper and lower Quality Electronic Inspector, left in the hands of some of the average-skilled technicians of the World”

In the following, we’ll introduce the study of a pattern observed worldwide after 2004 in the operative reality of around one-hundred Electronic Inspectors sold to be operated in-the-Machine (Labeller, Filler, Capper, Closer or Seamer). Follow us in this Root Cause Analysis Case Study and you’ll discover what really is presently hidden under the surface of that beer.

The Electronic Inspectors, whatever their Vendor, are built in two configurations:

standalone,
in-the-Machine.

Standalone configuration

Standalone configuration is by far the cheapest.

2-5 times cheaper than the in-the Machine. It does not include any connection, sensors, inspections, detectors nor logic relation with a precedent Labeller-, Filler-, Closer- or Seamer-Machine.

Its:

tasks are limited to handle a single Shifting-Register, rarely a couple of them;
hardware is reduced to the minimum, typically one Trigger sensor over which the unique Shifting-Register is logically built, inspections and a rejector.
fitting, wiring, starting and commissioning are accomplished in a limited time and, not being particularly complex tasks, they do not require the typically few available top-skilled service technicians.
In systhesis: when configured to operate Standalone, all Inspectors imply an installation task that all of the Optoelectronics' service technicians fulfil.

In-the-Machine configuration

The Electronic Inspectors with locating positions and/or inspections in-the-Machine (Labeller-, Filler, Closer-, Seamer-Machine) are complex and their:

tasks extended to handle several Shifting-Registers, typically two minimum;
hardware is maximised, several Trigger sensors (inductive and optic) over which the various Shifting-Registers are logically built, many inspections and frequently more than one Rejector.
their complexity is reflected in their pricing, always a factor 2-5 more expensive than the corresponding models operating standalone,
years of practice, trainings, deep and true comprehension of the Shifting-Register's concept, are pre-requisite to an accomplished Commissioning. Commissioning honouring the Contract between an OEM or Vendor and a Food and Beverage Bottling and Packaging Company, also respectful of a row of legal requirements imposing, as an example, that the Machine Safeties cannot be left systematically disabled to the unaware Customers.

Human-factor does matter

Commissionings can only be named and underwritten that way in a worksheet whose siognature is asked you when:

honouring the Contract between an OEM or Vendor and a Food and Beverage Bottling and Packaging Company,
respectful of a row of legal requirements imposing, as an example, that the Machine Safeties cannot be left systematically disabled to the unaware Customers.
We are suggesting the Readers that the service technician’s skills are part of the final added-value of the Electronic Inspector, because they are those one who shape the future years of the equipment. World’s most expensive and higher Quality Electronic Inspector, left in the hands of some of the worst technicians, always perform much worse than World’s cheaper and lower Quality Electronic Inspector, left in the hands of some of the average-skilled technicians of the World.

Comparing Standalone & in-the-Machine installations’

pricings

How to predict what should be the pricing of an Electronic Inspector’s installation, say its fitting, wiring, start-up, Commissioning and Operators’ Training ?

Examing a posteriori many hundredths of different installations of Electronic Inspectors in Beverage Bottling Lines:

where the above named installation activities had really been made, and made the only way the laws let them be valid in your country, because conformal to Safety rules and other technical good practices it is possible to see that a relation really exist,
in different countries,
part of Projects of Bottlers in competition (example, Coca-Cola vs. PepsiCo, AB InBev and SABMiller), whose Quality standards are different,
configured with all of the existing spectrum of inspections,
processing all existing kinds of containers (glass-, PET-, PRB-bottles, metal cans, crates and cases, etc.),
from a wide range of productions, from 8 000 til 92 000 containers-per-hour,
regression analysis shows an approximate but straightforward relation deriving be the comparison of the prices of the equipments, when the installation activities are not included. The installation pricing factor has empiric origin, nor we’d imagine what another way could be imagined to observe tendential relations which can only be obtained by linear regression studies a posteriori.

As an example, if a Full Bottle Inspector costs 8000 € , ~10000 $ (weighs net 18 kg) is mainly but not only because that amount is proportioned to the sum of the values of its mechanical, pneumatical, optoelectronics, automation and documentation components.

Another kind of Full Bottle Inspector of that same Vendor, priced ten times more, i.e., 80000 €, ~100000 $ (weighs 138 kg) shall need installation activities extended approximately to a duration 3.5 times longer than 8000 € model, needing just 3 days. Superior model costs ten times more than the basic: it sports many more functions and optionals to install (Rejectors, Triggers, cables, sensors), fit, wire, start, commission and finally train your staff.

Five basic questions submitted to you own critical thinking:

an Electronic Inspector needing 10 man*day of activities in your site, has been (strangely) delivered you after just 5 man*day ?
What let you feel comfortable with the idea that its configuration is what you paid for ? What techniques you used to test it ?
Maybe some test bottles had been passed one hundred times before to decide ? If this is the case, you have to know this is the kind of inspection a cheap Standalone Electronic Inspector does. An expensive in-the-Labeller Machine is paid to do many more additional useful things (like, advanced sampling or inspection in-the-Labeller) than just inspection at-the-Conveyor where the test bottles have been introduced.
Would you order a new car, without to be informed before about its configuration, motor and performances ? We don’t think so, then it makes sense the following question:
Have you received a precise listing of the functions assured you (Electronic Inspector’s Technical Guarantees) by the OEM or Vendor ? If not, why not ?

Why Containers' Triggering is vital

To let the Reader of these notes fully understand why all of the Triggering subject has so many pages developed to in this web site, there is to remark that:

the identity of whatever object is its most fundamental information. It’d make no sense at all to speak of the “defective status of a container” in presence of ambiguity about “what container” is defective. In other words, containers’ Tracking, is much more important than whatever inspection, say whatever measurement of one of the physical properties of an object;
when comparing Food and Beverage Packaging Industry with the Pharmaceutical Packaging Industry, we discover that the former with few exceptions discards as dangerous the rejection over an external Conveyor of the containers detected “defective” in-the-Machine. Following Pharma safety standards and customs, detection and rejection have to happen both in-the-Machine. The rejection has not to happen out of its Shifting-Register, one truly satisfying the requisites of rigidity and impossibility of the containers’ sliding out of the cells them attributed. Pharma Industry refrains to operate like Food and Beverage Packaging Industry operates following the OEMs and Vendors’ design choices;

Machine-Conveyors-Inspector synchronisation

Whatever the case, then also for relatively slow speed Labellers (<1.0 m/s), it is vital to synchronise the ramp-up and ramp-down phases of the Labeller and of the out feeding Conveyor, so that their speed difference results always <0.1 %.

0.1 % is a value knowingly close to the nonlinearity limit of the commercial Frequency Converters. Say the equipments regulating the speed of the motors in the Labeller and in the Conveyance systems. As an example, 0.1 % of divergence between bottle in-the-Labeller and same bottle at-the-Conveyor, at a speed of 1.5 m/s are 1.5 mm. 1.5 mm may appear a small divergence. But it is the maximum which can be allowed to be, keeping apart the today rare cases where containers’ speed is relatively slow (<0.8 m/s).

Containers’ speed, being related to the containers’ kinetic energy following a quadratic law, enhances the slidings’ occurrences and then their negative effects.

False Triggers and Data Sheets

The Trigger controlling the Rejector, say the last one immediately before the Rejector, shall be exposed to count False Triggers, corresponding to bottles whose identity is unknown because lost. False Triggers which, in your own full interest, have to be absolutely be rejected by the Inspector, also if part of them corresponds to correctly labelled bottles.

To let the Reader of these notes fully understand why all of the triggering subject has so many pages referred to in this web site, there is to remark that:

the identity of whatever is the most fundamental information; it’d make no sense to speak of the defective status of a container in presence of ambiguity about “what container is defective”.
the entire Pharmaceutical Industry discards and avoid as excessively dangerous the rejection of containers detected “defective” in-the-Machine, over an external Conveyor; detection and rejection have to happen in-the-Machine and not out of its Shifting-Register truly satisfying the requisites of rigidity and impossibility of movement of the containers out of the cells there attributed. In brief, Pharma Industry refrains to operate like Food and Beverage Packaging Industry is induced to operate by the choices of the OEMs and Vendors;
How many of them has to be expected corresponding to correctly labelled bottles, then False Rejects ? A quite precise answer is given by the Inspector Counter menu for False Triggers, visible below as 0.01 %. Exactly that shall be the portion of the total False Rejects due to Falsely Triggered bottles. The mere existence of the Container Presence sensor shall force this rejection. Do not forget what seen above about the Transfer Point of the Labeller Machine's out feed starwheel.

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99.5 % of the non-labelled bottles to the Market

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This website has no affiliation with, endorsement, sponsorship, or support of Heuft Systemtechnik GmbH, MingJia Packaging Inspection Tech Co., Pressco Technology Inc., miho Inspektionsysteme GmbH, Krones AG, KHS GmbH, Bbull Technology, Industrial Dynamics Co., FT System srl, Cognex Co., ICS Inex Inspection Systems, Mettler-Toledo Inc., Logics & Controls srl, Symplex Vision Systems GmbH, Teledyne Dalsa Inc., Microscan Systems Inc., Andor Technology plc, Newton Research Labs Inc., Basler AG, Datalogic SpA, Sidel AG, Matrox Electronics Systems Ltd.

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