Pudding Manufacturer

Pudding Manufacturer hits sweet spot thanks to WinSPC

Background

As a division of one of the nation's largest food manufacturers (with over 30 billion in annual sales), this particular grocrey division supplies restaurants, foodservice customers and branded food products for grocery stores. They chose WinSPC to control quality and costs on a snack pudding line.

“It’s critical to know each pudding cup’s weight and how it’s trending to prevent a runaway problem. WinSPC pays for itself by eliminating just one of these types of problems.”

--Quality Manager
Grocery Products Division of one of the nation's largest food manufacturer

Challenge

The grocery products division makes and packages multiple flavors and styles of pudding. In order to ensure high quality and consistency, it needed to tightly control several processes such as flavor, color, viscosity, pH and unit weight.
The division especially wanted to improve control over individual cup weights. Since it produces several million pudding cups per year, light weight inaccuracies over time can be prohibitively costly. Underfilled cups are scrapped and over-filled units give away product.

In addition to the identification of cup weight problems, any shutdown of a line for corrective action also adds several hours of down time for mandatory cleaning and sterilization before the line can be restarted. The Quality team, therefore, wanted to prevent cup weight problems and pinpoint their root cause so they could reduce costly downtime.

Implementation

The company chose WinSPC for the following reasons:

WinSPC automatically accepts real-time data through a variety of input devices
WinSPC enables the manipulation and correlation of data to produce key decision-making reports
WinSPC has a customizable operator interface that can be easily modified to support corporate initiatives
WinSPC solution delivery has been instrumental in our success

Results

WinSPC continues to allow the Division Quality team to maintain consistent unit weight, therefore, greatly reducing costly product overfills, scrap and downtime. By closely monitoring the filling process through WinSPC, the team was also was able to revise machine maintenance schedules to support optimum performance.

Benefits

The Divission cited the following benefits after implementing WinSPC

Solved fill weight problems in one-third the time by being able to predict problems through trending analysis
Reduced downtime and increased yields
Attained ROI in three months
Reduced unnecessary machinery cycles
Enabled the staff to run very lean sure to automated data collection

Get Started

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