Unit 3 - Line Operations Flashcards
(100 cards)
1
Q
What four main factors should be considered when specifying requirements for a new or upgraded packing line?
A
- Information about the product
- Information about demand
- Off-line and QA factors
- Information about machine supplier
2
Q
What 6 pieces of information do you need about a product when specifying a new packing machine?
A
- Physical form, state, and size
- Is it hazardous?
- Is it fragile and needs a barrier?
- Shelf-life
- Cleaning requirements for the line
- Storage
3
Q
What 3 pieces of information do you need about product demand when specifying a new packing machine?
A
- How many product variants
- Run lengths and sales volumes
- Pallet formats and tertiary packaging
4
Q
What 8 pieces of information do you need about off-line and QA factors when specifying a new packing machine?
A
- Manning and engineering levels
- Skill required to run line
- Training
- Health and safety regulations
- Hygiene requirements
- Layout and space constraints
- Environmental restrictions such as waste disposal, noise restrictions, and vehicle movement restrictions
- Capital budget
5
Q
What 7 pieces of information do you need from a machine supplier when specifying a new packing machine?
A
- Total cost of supply including installation and spares
- Lead time
- Additional services such as air, water, and energy consumption
- Who will manage the installation?
- What training is available?
- Acceptance and hand-over process
- Warranties and performance guarantees
6
Q
Give 5 advatages of packing line automation
A
- Increased line output
- Consistent quality
- Hygiene
- Safety
- Economics (people reduction)
7
Q
Give 4 disadvantages of automated packing lines
A
- Materials running on line will require better consistency and tighter tolerances
- Minor adjustments may be more complex
- Greater operator skill is required
- Frequent changeovers can cause lost time
8
Q
Name and describe the 5 key measures of packing line efficiency
A
- Design speed - a theoretical capacity, usually given as containers per hour
- Capacity - the upper sustainable speed when producing acceptable packs
- Running speed - the actual operating rate at a given point in time
- Output rate - a line’s output of acceptable product in a given time
- Efficiency - the ratio of output over input, usually given as a packaging actual output as a % of the theoretical output over a given period of time
9
Q
Give 6 reasons why packing line efficiency is measured
A
- Continuous improvement - identification of areas of loss and implementing corrective action
- To assist planning to forecast output and update plans to meet customer demands
- To motivate employees as part of a bonus or reward scheme
- For competition between sites or shifts - not desires as can lead to bad co-operation between sites or shifts in order to win
- To enable action to be taken to correct issues or change plans to meet demand
- For making decisions on future expansion, using current performance factors when purchasing new equipment or selecting suppliers
10
Q
Name 9 things that affect packing line efficiency
A
- Number of machines or processes in line - the more processes, the greater the effect
- Interdependence between processes and how one affects the next
- Machinery design - is it easy to access and clear jams?
- Machinery adjustment and SOPs
- Consistency of materials as faster machines have less tolerance of input variations
- The quality and frequency of maintenance
- Machine age and quality of asset care
- Difference in product being packed
- Operator and engineer skill levels, level of training, and motivation
11
Q
Name 2 ways of ensuring the filler on a packing line does not stop
A
- Have higher speeds before the filler
- Have each machine automatically adjust its speed depending on adjacent machine conditions
12
Q
Name 4 things that must be determined before planning overall line output
A
- Running speed variations
- Wastage
- Breaks and shift changes
- Machine availability due to maintenance and breakdowns
13
Q
What does using accumulation help reduce?
A
Reduces the incremental effect of inefficiencies between key processes caused by normal machine stoppages such as reel changes on a flow wrapped
14
Q
When must accumulators be installed on the line? Give 3 examples
A
- Must be installed after non-interruptible operations such as:
- Baking ovens
- Chocolate waterfalls
- Heat treatment
15
Q
What should be considered when using accumulators in regards to batch and date coding?
A
Accumulator residence time and the effect on date coding should be considered - must occur before accumulation otherwise the time will include the amount of time the product has sat in the accumulator, which could lead to problems with traceability across multiple batches
16
Q
Name the two types of accumulator and if they are FIFO or LIFO
A
- Liner flow conveyors - FIFO
- Bi-directional tables - FIFO and LIFO
17
Q
What must happen to packs after they have been in an accumulator?
A
Packs then need to be sorted and oriented for the next operation
18
Q
What determines the maximum speed of a production line?
A
The slowest machine
19
Q
What does each machine’s efficiency represent?
A
How reliably or consistently the machine operates, usually as a %
20
Q
How do you calculate overall line efficiency?
A
Multiple the efficiencies of all machines in the line
21
Q
How do you calculate the actual output rate of a production line?
A
Multiply the bottleneck speed by the total line efficiency
22
Q
Why is it important to consider accumulative effects in a production line?
A
Because small inefficiencies at each stage add up and significantly reduce total output
23
Q
What is the purpose of using accumulation in a production line?
A
To increase output and keep parts of the line running when other parts stop.
24
Q
How is a production line typically divided when using accumulation?
A
Into sub-units (e.g. Sub unit A and Sub unit B) with accumulation placed between them.
25
How do you determine the maximum line speed when using sub-units?
It is limited by the slower of the two sub-units.
26
What happens if a machine like the filler stops working?
The accumulator allows downstream machines to continue operating temporarily.
27
Why might the position of the accumulator be changed?
To test different configurations for maintaining flow and improving line efficiency.
28
What is the purpose of using combined block modules in high-speed liquid filling?
To minimise space and reduce the number of operators needed.
29
What are 3 examples of typical block module combinations?
PET preform blower – labeller – filler/capper
PET preform blower – filler/capper
Filler/capper – labeller
30
Why do block modules require high-quality materials and operator training?
Because they run at high speeds with no accumulation, meaning there is no buffer if something goes wrong.
31
What is the consequence of not having accumulation in block modules?
Rejected packs cannot be reworked, so repeated stoppages cause high wastage and increased costs.
32
What passes directly from stage to stage in block modules?
The packaging materials — without any buffering or accumulation between stages.
33
What does OEE stand for?
Overall Equipment Effectiveness.
34
What does OEE measure?
A combination of availability, performance, and quality.
35
What are the three types of losses that OEE accounts for?
Availability loss: Planned and unplanned stoppages
Performance loss: Idling and minor stops (e.g. pack jams)
Quality loss: Rejects from underfills, start-up, or out-of-spec product
36
What is the formula for calculating OEE?
OEE = Availability × Performance × Quality
37
Does OEE include scheduled non-productive time like breaks or weekends?
No, it only measures losses during scheduled production time.
38
What would an OEE of 100% mean?
Perfect production — no downtime, no slow cycles, no rejects (which is practically impossible).
39
What is changeover time and how is it measured?
It's non-productive time, measured from the last saleable product of one run to the first saleable product of the next run.
40
What are the four main steps of a changeover?
Preparation – Gather parts, tools, and operators
Changeover – Switch components
Adjustment – Set up and fine-tune the machine
Pre-start – Run-in and checks before restarting production
41
What’s a common practice to speed up the preparation step?
Using a changeover trolley with all required parts prepped offline and ready to go.
42
Why should changeovers be monitored and optimised?
Because a fast changeover is pointless if it causes high scrap or wasted materials in the next run.
43
What are modular machines and how do they help with changeovers?
Instead of switching individual parts, a full module is swapped out.
Example: A bottle labeller with different modules for paper vs plastic labels.
44
What are linked machines and how do they reduce changeover time?
Machine settings like palletisation and BBE codes are stored in a central system and downloaded automatically to the machine.
45
How does container profile affect packaging lines?
It impacts how packs move on conveyors — round containers are easiest to handle, while oval ones with narrow radiused profiles are more likely to jam.
46
Why are single contact points on containers a problem?
They can cause containers to lean and fall, leading to jams, damage, or breakage.
47
How can pack design reduce the risk of damage on conveyors?
Design to reduce impact
Match conveyor speed to fragility
Use build-back sensors and feedback systems to ease pressure when conveyors are full
Use wider contact areas or multiple points of contact
48
How can changeover time be reduced through container design?
By keeping the same container width and only adjusting height if volume increases.
49
What are other ways to reduce changeover times?
Keep coding panels the same height and orientation
Use consistent label height and width
Maintain the same tray wall height
50
What factors influence the ability to hold stock of finished products?
Shelf-life, forecast accuracy, and customer demand variability.
51
What are the pros and cons of longer production runs?
Pros: Increased OEE
Cons: Higher stock holding costs and increased risk of waste with short shelf-life products
52
What are the pros and cons of shorter production runs?
Pros: Lower finished stock holding
Cons: Lower OEE, more cleaning cycles, more waste, and increased risk if demand spikes unexpectedly
53
What is EOQ (Economic Order Quantity)?
The point where production and holding costs are balanced with commercial risks.
54
What is the customer service risk of short runs?
An unplanned spike in demand may lead to stockouts and poor service.
55
Why should packaging materials be moved from the warehouse to the line in advance?
To give them time to acclimatise before use.
56
What should be done with material and batch details during use?
They should be scanned or logged at the time of use for traceability.
57
Why are quality checks and routine sample collections important?
To support off-line testing and ensure consistent product quality.
58
What should be done with packaging materials used to deliver components?
They should be removed from the line once they've served their purpose.
59
What should be done with process scrap and underfilled packs?
They should be removed promptly to avoid clutter and maintain efficiency.
60
What should happen to unused packaging after a run?
It should be returned to the warehouse for reuse in future runs.
61
Why is proactive cleaning and maintenance important?
It helps prevent breakdowns and maintain smooth operation of the line.
62
Why is production planning and material supply important?
To ensure materials are always available, preventing production delays.
63
Why are specifications and contracts important in production?
They ensure clarity, consistency, and that suppliers meet required standards.
64
What is the purpose of goods-in and material receipt checks?
To confirm incoming materials are correct, undamaged, and meet quality standards.
65
How does waste separation and recovery improve efficiency?
It reduces disposal costs, supports recycling, and improves plant cleanliness.
66
Why is holiday and sickness cover important?
To maintain staffing levels and avoid interruptions in production.
67
Why must water, air, and power be reliable at all times?
Because they're critical utilities — any disruption can halt production entirely.
68
What factors determine the frequency and level of inspection?
Consequences of failure
Product type (e.g. food vs. pharmaceuticals)
Process risk level
Detection systems available
Industry guidelines (due diligence)
Customer requirements
Legal requirements
69
What should be considered when setting up quality assurance and control checks?
Risks minimised (based on risk assessment & CCPs)
Number of checks needed
Cost: in-line equipment vs. manual checks
Reliability and repeatability of manual checks
Sensitivity of the checks
70
What are the three areas of product inspection?
Production line requirements
Supply chain requirements
Consumer requirements
71
What are examples of production line inspection checks?
Reject damaged or defective packs
Identify incorrect packaging materials in supplier deliveries
72
What are common supply chain inspection checks?
Barcodes scan correctly
Product is clearly recognisable
Tamper-evident transit packaging
Traceable date/batch details
Product is correctly packed in secondary and tertiary packaging
73
What are key consumer-focused inspection checks?
Easy-to-open/close packs
Tamper evidence intact
Correct weight, volume, and fill level
Print is clear and legible
No leaks, contamination, or sharp edges
Correct product inside
BB (Best Before) date is legible
74
Where is off-line pack inspection usually carried out?
In a quality station next to the line or in a lab, using semi-automatic or automatic equipment.
75
How are samples selected for off-line testing?
Samples are taken at regular intervals from the line to be tested.
76
Is off-line testing usually cheaper or more expensive than in-line testing?
Cheaper — but it's often destructive.
77
Why do off-line test results have greater variance?
Because of human interaction — for example, closure release force depends on grip strength and rotation speed.
78
What are some examples of off-line pack tests?
Vacuum tests for dip pots
Testing bonding quality in cans
Using a torque meter to measure cap tightness
79
What is the main advantage of in-line pack inspection?
It provides 100% inspection of all packs with instant feedback and consistent measurement, allowing defective packs to be rejected on the line.
80
How do cameras help in in-line inspection?
They scan 360° around the pack, compare it to a standard image, and reject it if there's a mismatch.
81
What is a major drawback of in-line inspection systems?
They are very costly to install and maintain.
82
Why is correct setup of in-line systems important?
To avoid false rejects or missed defects, which can lead to increased waste and costs.
83
Why is calibration important in in-line inspection systems?
Because they detect defects the human eye cannot, so they need regular calibration and clearly defined reject criteria.
84
How can PET bottle inspection systems improve production?
They can detect wall thickness issues and provide feedback to adjust heating and blowing parameters further up the line.
85
What can X-ray inspection systems detect?
Damaged or missing contents and physical contamination.
86
How do sensors work in MAP (Modified Atmosphere Packaging) packs?
They can measure oxygen levels without breaking the film or seal.
87
What is the purpose of the Weights and Measures (Packaged Goods) Regulations 2006?
To recognise the statistical nature of filling and allow some under-filled packs as long as the average fill is greater than or equal to the stated quantity.
88
What are the three key rules for compliance under this legislation?
Actual contents should not be less than the nominal quantity on average
Only a small proportion of packs may be below the Tolerable Negative Error (TNE) – defined as T1
No pack should be more than twice the TNE short – defined as T2
89
What symbol can compliant packs display under this regulation?
The estimated (e) sign
90
What must be in place for a pack to display the e-mark?
Quantity and labelling meet legal requirements
Contents are measured or production checks are carried out using approved procedures
Documentation is available for inspection, showing necessary checks, corrections, and adjustments
91
How does TNE change with different nominal quantities?
It varies between 1% and 9% depending on the pack size, and is always rounded up to the nearest tenth of a gram or millilitre.
92
Do the Weights and Measures (Packaged Goods) Regulations 2006 apply over the entire shelf life of a pack?
Yes — the regulations apply throughout the pack's shelf life. This means allowances may be needed if the pack naturally loses weight or volume over time.
93
How can a controlled filling process help save money in packaging?
By reducing variance in container volume and the filling process, manufacturers can lower the average fill level while still meeting T1 and T2 legal requirements — saving product and reducing overfill waste.
94
What are examples of immediate issues that may need solving in production?
Checking machine settings
Changing to a new batch
95
What should be used to solve long-term or recurring problems in efficiency or quality?
A Root Cause Analysis (RCA) process.
96
What are the key steps of a Root Cause Analysis (RCA)?
Define the problem
Identify all possible causes
Eliminate each cause through testing and evaluation
Identify the root cause(s)
Implement corrective actions to prevent reoccurrence
97
Why is operator training important for problem solving?
It ensures staff understand how to properly use materials and machinery, reducing errors and downtime.
98
What are the hygiene and safety requirements when solving production problems?
There must be no risk to consumer illness or safety
Businesses usually require BRC accreditation and a HACCP plan
99
What should be checked before installing a new machine or line in a production environment?
It is vital to check and compare machine requirements and tolerances with the materials you expect to run.
100
What preparations might be needed months in advance before a new line starts?
You may need supplier tooling and materials to be ready several months before the planned production start date.
