May 3, 2014
A recognized leader in gum, mint and candy manufacturing, with products distributed throughout the globe, recently implemented WinSPC software to reduce costs while ensuring compliance with its high product quality standards.
The implementation is the first of multiple sites planned for the company’s global manufacturing operations.
Although the project leaders identified many high-value targets, the path to better control began with simple objectives. The first objectives were to capture the attributes for in-process sheet goods and to achieve classic weight control for final products with the help of WinSPC. The DataNet services team was engaged to assess, plan and provide a solution for these short-term needs.
The solution improved production visibility and delivered the process control capability necessary to reduce costly production variability. The services team worked closely with the company to provide education and guidance to leverage the new detection and prevention capabilities. Importantly, training and communication with line-operators was undertaken to help drive successful user adoption.
The company initiative is now fully on its way to achieving greater gains as automation and integration expand to more than fifty locations throughout the first facility. The company faced challenges controlling variation on production lines dominated by manual operations and influenced by environmental factors.
Lacking adequate process visibility and the control to consistently achieve its exacting quality standards, large volumes of out-of-spec materials were being captured and re-blended back into production to achieve the target quality parameters. In addition, various world destinations imposed different standards for labeled content compliance and product acceptance.
Waste occurred due to the difficulty in maintaining final physical traits in compliance with the various labeled product specifications. The company recognized that a huge savings was possible if it could implement a system to improve process control and achieve more consistent outcomes.
Even though the initial implementation was simple, the DataNet services team realized that the long-term objectives of this customer required much deeper analysis of production processes and outcomes. In order to prepare the company for long-term success, the DataNet services team leveraged extensive industry experience to help the company organize and configure its production control systems for these future gains.
The DataNet services team demonstrated how a small investment to maintain relationships concerning the product formulas and varieties would yield deeper insight into the sources of variability and enhance field traceability investigations. By implementing a solution using this guidance, the system will accumulate a wealth of knowledge about the inherent relationships within production contexts and provide the basis for future investigations to uncover even greater savings. Ultimately, the company will gain additional insights and capabilities down the road, without any additional cost now or later.
Once these production areas come under control, the company plans to improve their quality management by implementing process control throughout product packaging and beyond to include traceability for field product performance.
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About DataNet Quality Systems
DataNet Quality Systems empowers manufacturers to improve products, processes, and profitability through real-time statistical software solutions. The company’s vision is to deliver trusted and capable technology solutions that allow manufacturers to create the highest quality product for the lowest possible cost. DataNet’s flagship product, WinSPC, provides statistical decision-making at the point of production and delivers real-time, actionable information to where it is needed most. With over 2500 customers worldwide and distributors across the globe, DataNet is dedicated to delivering a high level of customer service and support, shop-floor expertise, and training in the areas of Continuous Improvement, Six Sigma, and Lean Manufacturing services.