The Cup Filling Process

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The Cup Filling Process
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The Goal !

• What is one of the primary goals related to the
  management of the cup filling process?

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(No Transcript)
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Factors Affecting Fill Weights

• Factors affecting the net weight of the cup
  include the explainable factors
• Lane (4 levels)
• Phase (2 levels)
• Time of Production
• Unknown Factors
• and the unexplainable factors
• Random Noise

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Analysis of Process Factor Effects
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Analysis of Process Factor Effects
Production Condition Lane - 1 Phase - 2
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Sampling Design

• A sampling design was employed in which 1000
  consecutive cups were sampled from each of the
  four filling lanes.
• The gross fill weights were measured on each cup.
• How should we analyze these 4000 fill weights in
  order to understand and reduce the variation?

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Histograms Created from the Data Generated by the
Sampling Design
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The Cup Filling Case Study
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The Cup Filling Case Study
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The Cup Filling Case Study
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The Cup Filling Case Study
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The Cup Filling Case Study
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Analysis of Process Data
Histogram for the Fill Weights Produced by the
Original Process
Histogram for the Fill Weights Produced by the
Redesigned Process
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The Cup Filling Case Study

• If the effects of the active factors creating
  variation in fill weights can be removed from the
  process, the process capability will be improved
  and the target weight can be reduced.

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Summary of the Capability Analysis

• The final analysis performed by the team was to
  determine the cost savings to the organization
  achieved by identifying and removing the pressure
  effect through the redesign of the filling
  process piping system.
• As one example, prior to the redesign, the
  process average was set at a minimum value of 237
  gms for a specific product.
• After the process redesign and the associated
  reduction in variation, the process average was
  reduced to 230 gms for a net savings of 7 gms per
  cup.
• The machine was designed to produce 20,000,000
  cups per year, and the average cost of product
  filled by the machine was 0.00068/gm.
• Therefore, the estimated savings in raw material
  were 20,000,000 x 7 gms x 0.00068 95,200 per
  year.

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Discussion Topic

• What is the fundamental issue with respect to the
  control and improvement of the cup filling
  process?

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Discussion Topic

• What were the fundamental components of the
  strategy leading to the improvement of the cup
  filling process?