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:

IntroductionIn the following, we’ll introduce the study of a pattern observed worldwide in the period 2005-2014 in the operative reality of around one-hundred Electronic Inspectors sold to be operated in-the-Machine (Labeller, Filler, Capper, Closer or Seamer). …

Case Study Sampling Table always jammedIntroductionTypical problems in a Food and Beverage Bottling Line derive by missing materials like motors, Frequency Converters, detectors, etc. In the following we’ll briefly study a Case where the “material” was much more than necessary. …
Case Study The Brewery which considered the TechnicalGuarantees part of a Contract to be honoured  ROC-curve of a Fill Level inspection. Imagine to pass 1000 times a test container through one and the same Electronic Inspector equipped with a dual Fill Level Inspection: X-ray and High Frequency (or, Optic with camera). …
IntroductionPowerade® is a famous energy beverage, the first in a row of energy drinks with great success launched in the World, after 1988. In July 2002, The Coca-Cola Company® updated the bottles of the standard Powerade to a new sport-grip bottle. …
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. …

Case study 1 year of Production lost   In the following a case where the Machine blamed by the Bottler never functioned correctly since the first day. 18 months later, and after two different analysis made by elements acting in conditions of …

Case study Cap presence control of sensitive beverages in 2001“X” is a great dairy filling and packaging plant. Here were installed, started and commissioned two standalone Full Bottle Inspectors in a new Aseptic Line for PET-bottled dairy products. …

Case study Cap Presence control of sensitive beverages in 2010Introduction “Y” is a great dairy filling and packaging plant. Here it has been installed a standalone Full Bottle Inspector in a new Aseptic filling Line for PET-bottled dairy products. …

Case study99.5% of the non-labelled bottles sent to the Market Non labelled and flagging-labelled bottles, manually rejected at the outfeed of a Labeller Machine. Manually rather than automatically rejected by the inspection system, because of a design-error in its configuration, amount of tracking Triggers photocells and Encoders. …

Case StudyCanning Line’s Layout Relevance   IntroductionNo one of us has X-Ray's radiographic eyes. Because of this obvious reason, the cans’ content cannot be visually verified if, due to any reason, the Full Can Inspector is not active. …

Case study Electronic inspection of Pharmaceuticalsin-the-Machine-Cycle When speaking of guarantees of asepticity, Pharmaceutical Industry is since many decades what really and only retains the maximum know-how. …

IntroductionThe Pharmaceutical field is the origin of the technologies adopted today in the Aseptic filling, closing and inspection of beverages without any added preservatives. Are the Food and Beverage Packaging standards competing with the Pharma standards of, as an example 10 years ago ? …

Case HistoryGold-made electronic cardsImagine 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. …

The “Device”Fusing, considered the Root Cause of whatever explosion, is just one superimposed component of an extremely longer sequence of conditions before and after, greater and smaller, than the Fuzing. …
- Expensive in-the-Machine Electronic Inspectors reduced to cheap Standalone
- Sampling Table permanently jammed
- Filling Level Technical Guarantees
- The Cardboard Label Inspector
- 27 % rejects stopping all days a Bottling Line
- 1 year of production lost
- Cap presence control of sensitive beverages in 2001
- Cap presence control of sensitive beverages in 2010
- 99.5 % of the non-labelled bottles to the Market
- Canning Line's Layout relevance
- Pharma’s in-the-Machine-Cycle electronic inspection
- Leaking Pharmaceutical Containers
- Gold-made electronic cards
- SAFF-sequence Topology
- Human-factor, industrial design and nuclear disasters
- A seismic Incident
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.