Missing Parts in Packaging Dunnage 2

[Ahmed Medani]

in the plant that am working at we have an issue of operators failing to completely fill the packaging containers with parts, and dunnages end up being sent to the customers with missing parts.

we've been trying to eliminate this issue by introducing a camera system that helps counting the parts in the dunnage, but due to the misty environment we were unable to implement that.
We went forward with implementing a weight scale system to weigh the whole dunnage (using load cells) with the parts included and introduced a threshold in which the machine will sound an alarm if some parts are missing.
Problem is, the system is too complicated to install and has a lot of limitations and complications. For example, weight variations are significant since the containers are sitting on a pallet lifter with a turn table on the top, which impose a lot of weight variations on the load cells during movement.

Since the project was assigned from out QC department thats why I posted this here. Did anyone encountered this problem before? If so please let me know how did you approach it.

Thanks in advance

 

[3DDave]

What's the motive for operators to lie? Fix that.

 

[MintJulep]

3DDave is spot on.

Thus far you are guilty of skipping step 1. "Identify the cause of the problem."

 

[Ahmed Medani]

no one said that operators are lying to us !. They basically pack 6 layer pallets during production so it is normal that due to human error they forget to pack some of them.
the whole point of the project is to make sure they don't forget by counting the parts and unless the pallet is full the label won't be printed.

 

[3DDave]

They are misrepresenting the work they do. Sure. Be polite and don't call it lying to their faces as you fire them. But they aren't able to count in a job that requires an ability to count.

Because they are unable to count, put up a small wall with a door flap in it. Hook the door to a cheap mechanical counter so that each time a part goes through, the door counter does the counting for them.

My guess is someone is rewarding these workers for getting the pallets packed as fast as they can without regard to getting the right number of parts.

 

[IRstuff]

Or, the parts are sufficiently valuable that skimming is lucrative.

TTFN (ta ta for now)
I can do absolutely anything. I'm an expert!

https://www.youtube.com/watch?v=BKorP55Aqvg

faq731-376 forum1529 Entire Forum list

http://www.eng-tips.com/forumlist.cfm

 

[MintJulep]

Ok, you want to Poka-Yoke your packing process.

Are the individual widgets uniquely labeled? Perhaps with a barcode?

Scan each item item as it goes onto the pallet.

Or make a staging area where it's easy to count, then confirm that the staging area is empty before staging the next set.