Our survey on p. 64 documents the pitfalls packagers have experienced in collecting data, converting it into knowledge, and acting on it. But there’s no question that the payoff—boosting line efficiencies and correcting quality problems early—is too great to ignore. In the pages that follow, we present several successful data acquisition implementations.
Checkweigher helps reduce giveaway
User: Costco Wholesale Co.
Application: In-line checkweigher for packaging ground beef in chub packs and penny packs.
Data collected: Average weight, number of rejects, over/under weight.
Benefit: Provides real-time weight control of meat packs to reduce any giveaway over 10 lb. Meat supplier usually absorbs this cost because Costco sells the meat at a fixed price, regardless of actual weight.
Technology: Rockwell Automation PanelView and Allen-Bradley PLC communication network.
How it works: A running average weight is calculated in the checkweigher. The standard deviation is automatically measured for over/under. A signal is sent via network to the packers to increase or decrease product flow based on data.
Who uses data: Production staff and quality control.
Networks: Machine is feeding information to a PanelView system via Allen-Bradley PLC communication network.
Quote: “I think it’s going to work very well. So far, we’ve reduced our giveaway to a tenth of what it was.” —Liam Nestler, Costco Wholesale Co.
