Filling and packaging lines lose output through short stops, speed losses and rejects. The pattern of stoppages over a shift usually points at the machine that is starving or blocking the rest.
Common problems
Frequent short stops
Group stops by machine and reason code to find the one that is starving or blocking the line.
Running below rated speed
Compare actual and rated speed per machine, and look for accumulation conveyors that are full or empty.
Reject rate rising
Trend rejects by inspection station and product change to see when the drift started.
Evidence that helps
- Line stop log or OEE export
- Machine speed and counter data
- Reject counts by station
Work on burners, fuel trains, pressure vessels and electrical equipment must be carried out by qualified personnel following the manufacturer's instructions and local codes. Never bypass a flame safeguard, limit or interlock.