Abstract
This paper is based on bottling process optimisation through continuous improvement. A case study was done at XYZ company. The Six Sigma Define, Measure, Analyze, Improve, and Control (DMAIC) methodology revealed that the bottling and capping processes were producing defects at 3 Sigma level. The 5 Whys, Pareto chart, fish bone diagram, and Suppliers, Inputs, Process, Outputs, Customers (SIPOC) model showed that loose-capped bottles (31.6%), under-fills (29.2%), and empty bottles (28.9%) caused the highest cost through poor quality. The monitoring system was designed to monitor the applied torque value, the capping head status, and the beverage temperature upon leaving the heat exchanger. The cooling system on the mix processor was designed using the closed loop control strategy. If the beverage temperature is not within 1 or 2 degrees Celsius, it is directed to secondary cooling; otherwise, it proceeds. The glycol inlet valve is actuated such that the flow of the coolant is adjusted to ensure that the primary cooling is efficient. The results show that it is possible to operate production within the Six Sigma level.
Highlights
The surge in the globalisation of the beverage industry over the past few decades has led more companies to enter international markets
The results show that it is possible to operate production within the Six Sigma level
The sections that follow present the DMAIC stages followed at the XYZ Company
Summary
The surge in the globalisation of the beverage industry over the past few decades has led more companies to enter international markets This has resulted in an increase of innovative and cheaper products being produced under efficient processes [1]. Keeping up with the competition to satisfy the customer’s unquenchable thirst for low-cost beverages affects the company’s bottom line by creating the need for low production costs through reduced waste. Despite efforts to attain world-class beverage manufacturing, many companies still face the major challenge of high defect levels This is as a result of a lack of technology and a dependence on manual labour, to mention only two factors. This research, which is a case study from XYZ Company, is focused on reducing the defect level of the carbonated soft drink (CSD) filling and capping process
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