The Problem
A surplus of nerds scrap is building up underneath our busiest production line, costing the company tens of thousands of dollars per month,.
The Solution
While examining other factory areas, I noticed that one of our production lines used a different conveyor. This one did not utilize plastic joined panels but one rubber mold to deliver candies. This design has no gaps between barriers or panels and would immediately address the source of the spillage on the other line. Furthermore, it was being used right here in-house! I immediately gathered information on purchasing and installation costs and recommended we switch to this conveyor design, as this belt would perfectly eliminate the source of the scrap.
The Source
After investigating the mogul line, I determined the issue to be with the conveyor delivering candies from the production to the packaging floors. A closer look underneath the track revealed a constant spill leaking through. The conveyor being used between these two areas was not suitable for the small volume of the nerds being transported due to the gaps present between individual panels and the side barriers.
The Impact:
43,512 lbs. of scrap saved per month
$1.14 lost per lb. lost
Projected $593,688 Annual Savings
