Quality Integrators Corp

CA

QIC developed a web-based tool for a food processor, which was used to assess the validity of the specification limits for retail food package weights.

Typically, the production target for package weight will be slightly above the stated label weight in order to allow for the inevitable statistical variation that occurs in manufacturing.

However, after an implementation of SPC, it is usually the case that the manufacturing line becomes more efficient, resulting in a target that is now too high, which in turn, increases the likelihood of product giveaway. Therefore, the plants will analyze this data, usually on a yearly basis, to see if the target can be lowered. However, depending upon the number of SKUs and/or the amount of data, this can be a very onerous task weeks, if not months of work.

By developing a web-based retargeting application, QIC was able to provide this client with a tool that they could easily use to retarget their products, in minutes. We found that our automated solution typically reduces efforts by over 200%, allows for what-if situations, allows for more frequent retargeting, provides critical information to R&D and facilitates a secure audit procedure.

Our client list includes: Boeing, Dana, Gates, General Electric, Goodyear, IBM, Kraft Foods North America, Magna, Maple Leaf Foods, Parmalat.

A QIC total solution was implemented at a large food processor in July 2001. The solution includes automated weight control (Automated data feeds, realtime data analysis, realtime monitoring), user and management training, and work practice implementation and enforcement.

The baseline for a particular product was set at 1013.37 grams and the product had an established target of 1002.90 grams. Essentially, there is an opportunity to save over 1% (In otherwords, the customer is giving away 1% of product).

By the 18th month, the new procedures have resulted in reducing over-pack from 13.16 grams to 6.80 grams A reduction of 6.36 grams or 48% per package!

Multiply this by multiple numbers of products being produced at over 40 plants, and the savings are tremendous!

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