PROBLEM: EMPTY CEREAL

BOX' S IS BEEN DELIVERY

TO CUSTOMER

Solution Exploration
October 2013
Process
Cereal
container
Bag
Conveyor
Filled Bags
Conveyor
Conveyor
Filled cereals boxes
Filler element
Base
Base
Filled Shipments boxes
With cereals boxes
Base
Process
Cereal
container
Bag
Conveyor
Filled Bags
Conveyor
Conveyor
Filled cereals boxes
Filler element
Base
Base
Filled Shipments boxes
With cereals boxes
Base
Problem Understanding
Our company could be impacted on:

Cost to give an answer to customer
complains call.
Cost of manual lot process in customer
premises.
Cost of loose a customer contract
Cost of company reputation damage


Problems Analysis
Solution 1
With this option the cause <<Production line is not
separating empty cereals boxes from filled cereals
boxes>> is going to be solved allowing us to avoid
shipments with empty boxes.

Each complete shipment box must be tested in order to be
approved for shipment.
If one of the complete shipment boxs is rejected the box must
be inspected lo locate the empty cereals boxes

Solution 1
Advantages of this option:
Empty cereals boxes are going to be out shipment process.
Customer is going to have what he expect.
Extra costs to attend customers complains must be cut.

Disadvantages of this option:
The process is going to be working as it is, producing empty cereals
boxes.
Additional work must be done to take out empty cereals boxes from
shipment boxes.
Additional work must be done to refill shipment boxes with filled
cereals boxes.
Additional work will cause extra costs and time delivery delays.


Solution 2
With this option the cause <<Production line is not
separating empty cereals boxes from filled cereals
boxes>> is going to be solved allowing us to avoid
shipments with empty boxes.

Each Cereals box must be tested in line just in the filling
process in order to avoid sending empty cereals boxes to
shipment process
Empty boxes are going to be take out of production line

Solution 2
Advantages of this option:
Empty cereals boxes are going to be out of production line.
Customer is going to have what he expect.
Extra costs to attend customers complains must be cut.

Disadvantages of this option:
The process is going to be working as it is, producing empty
cereals boxes.
Empty cereals boxes are lost money.


Solution 3
With this option the root cause << Production Line
is not filling all the boxes>> is going to be solved.

Actions to be implemented:
The Cereal supply container must be monitored in order to
ensure the fill of cereals bag.
Guarantee the supply of the filled Cereals bag at the same time
that the cereal s box to be filled is in position.
Cereals box must be monitored to ensure that is already filled.
Empty cereals box must be removed from production line.


Solution 3
Advantages of this option:
The root cause of the problem is attacked and eliminated
The process is going to be ensured.
In case of empty boxes pass ahead of filled process step, empty box is
going to be separated from filled ones.
Customer is going to have what he expect.
Extra costs to attend customers complains must be cut

Disadvantages of this option:
If cereals container supply are out of minimum established
threshold, the process will be stopped.
If a cereals box empty events happen above some established
thresholds, the process will be stopped.

Tank You.