Inaccurate Packet Counts

Solution & Explanation

Understanding the Problem

To effectively address the issue of inaccurate packet counts, it's essential to understand the problem's context and scope. The supervisor is concerned about the inconsistency in the number of packets per box, which is meant to contain exactly 25 packets. Client feedback indicates a deviation from this standard.

Clarifying Questions

1. When did the issue start?

   • Understanding the timeline helps identify if the problem correlates with any recent changes in the production process or equipment.

2. Frequency and Nature of Complaints:

   • How many complaints have been received recently?
   • Are boxes consistently over-packed or under-packed?

3. Machine Specifications:

   • What are the machine's operational parameters?
   • Is there a history of similar issues?

Data Collection

1. Sample Measurement:

   • Collect data on the number of packets per box over several runs (e.g., 100 boxes).
   • Record the weight of each box and individual packets if possible.

2. Machine Logs:

   • Review logs for any errors, anomalies, or deviations during operation.

Statistical Analysis

1. Descriptive Statistics:

   • Calculate the mean and standard deviation of packets per box to see if the average deviates from 25.

2. Outlier Detection:

   • Identify boxes with significantly more or fewer packets than expected.

3. Control Charts:

   • Use control charts (e.g., X-bar chart) to monitor consistency over time.

Hypothesis Testing

1. Define Hypotheses:

   • Null Hypothesis (H₀): The mean number of packets per box is 25.
   • Alternative Hypothesis (H₁): The mean number of packets per box is not 25.

2. Conduct a T-test:

   • Perform a t-test to determine if the observed mean significantly differs from the expected mean of 25.

Machine Inspection

1. Calibration Check:

   • Ensure sensors and weighing mechanisms are calibrated correctly.

2. Mechanical Inspection:

   • Inspect for jams, misalignments, or faulty sensors in the packet feeding mechanism.

3. Software Verification:

   • Verify that the software controlling packet counts is functioning correctly and hasn't been altered.

Recommendations

1. Immediate Adjustments:

   • If calibration issues are found, adjust the machine settings to correct the packet count.

2. Long-term Monitoring:

   • Implement continuous monitoring to track performance and identify issues early.

3. Preventive Maintenance:

   • Schedule regular maintenance checks to ensure mechanical and sensor health.

4. Process Improvement:

   • Consider process changes, such as weighing packets individually if feasible, to improve accuracy.

Conclusion

By systematically analyzing the data, inspecting the machinery, and applying statistical methods, the root cause of the packet count inaccuracies can be identified and addressed, ensuring the machine operates as expected and client satisfaction is maintained.