8/13/2019 Root Cause Analysis Case Study Beverage Producer

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Helping international beverage producerunderstand and x costly system-wide problemsThis work was performed by the Sologic team when it was known as Apollo Associated Services, LLC.case study

One of the largest beverage producers in theworld thought it had one small problem atone plant with one conveyor belt failure.The company revisited the physical productspecications provided by the parts supplierand directed Chemir Analytical Services toperform a physical analysis of the belt.

Based on the results of those simple tests,the company and supplier determined thatthe problem was related to belt strength, sothe supplier replaced the belt with a modiedmaterial. Everyone thought the problem wassolved. Even when belts kept failing prematurely

just months after installation, the samereplacement solution was applied. Bothcompany and supplier tried to be conciliatory.The company did not want to alienate a supplier

by complaining too much. The supplier washaving trouble keeping up with the beltreplacement needs, but kept doing its best.

Two years later, the same problem startedpopping up at multiple sites. While they previouslythought they knew the source of the problem,now they were stumped. Different conditionsexisted at each site; different sites were usingdifferent belts with different materials fromdifferent suppliers that had different specs.Because data was housed in separate facilitiesand there was no system-wide view, no onerealized the widespread nature of the problem,

saw common threads, or understood thecollective costs to the company. Combiningfactors like down time and lost product, theproblem was worth millions of dollars.

Now realizing the problem might be biggerthan they thought, the company hired ChemirAnalytical Services to provide scientic analysis.Chemir started by asking big-picture questionsabout the resulting product, as well as revenueand productivity losses.

Immediately realizing the magnitude of theproblem in terms of lost revenue and system-wide reach, Chemir brought in its partner, theSologic team, to conduct a root cause analysisinvestigation. This would represent the rsttime that a problem at this company wasanalyzed using a structured problem-solvingmethodology.

Initially, many stakeholders had theories aboutwhat was causing the problems, but thosetheories were not based on fact. Applying root

cause analysis, Chemir and the Sologic teambrought together stakeholders from variousperspectives, including the supplier. This helpedeveryone understand the process and issuesmore completely.

After just a few hours, the group uncovered causes that no one had considered before.Beyond that, the causes were now supportedwith evidence, and documented in a cause andeffect chart. While some people were initiallyhesitant to support certain aspects of thecause and effect chart, after they witnessedthe thorough approach that incorporated allperspectives, they began to feel more comfort-able. Due to the detailed documentation, thecompanys corporate management was ableto clearly see the revenue being lost.

Because so many elements, circumstances andprocesses were inconsistent, Chemir andSologic team members analyzed the details todetermine cause and effect relationships thatwere both common and unique. For instance, theydiscovered that the problem was not completelyrandom it was only happening on bottle lines,not aluminum can lines.

While the beverage producer previously sawthis as a physical process problem and nochemical specs for the belt were provided bythe supplier Chemir and the Sologic teamrecommended that it was a chemical problem,so chemical analysis was needed. The companydecided to approve chemical testing of multiple

samples from multiple belts. By documentatingthe entirety of the problem, corporate could seethe cost benets of appropriately and thor-oughly xing the problem.

Test results enabled the investigation team topinpoint that the problem was related to theantioxidants in the belt material used on thebottle line. The lubricant that prevented beltsfrom snapping in the can line did not exist inthe bottle line.

This revealed the solution: a different lubricantwas needed on the bottle line, and it must beapplied consistently.

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action

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8/13/2019 Root Cause Analysis Case Study Beverage Producer

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case study

Millions of dollars were saved.

No more product was wasted as a result ofthis problem.

Down time no longer occurred as a resultof this problem.

The cause and effect charts were a valuabletool for presenting to management:

what the problem was

how the problem impacted the companysbottom line

how the problem was caused

what solutions were recommended

what resources would be needed toimplement those solutions

The company gained a clearer understandingof their processes, materials and parts.

The company realized the need for

consistency in processes, materials and parts.The costs associated with inconsistency weretoo great.

People learned the value of respectingdifferent perspectives and combiningsubject-matter expertise.

Chemir Analytical Services solves challengingproblems involving chemical analysis andmaterial testing. Since 1959 this independentlaboratory has solved thousands of issuesinvolving deformulation (reverse engineering),contaminant and impurity identication,product failure analysis, custom synthesis,analytical method development, patent,intellectual property, and other legal challenges for over 7000 clients.

Many of Chemirs clients are Fortune 500companies. The scientic staff of 35, including8 Ph.D. level chemists, uses state-of-the-artanalytical instrumentation and expertinterpretations to assist such industries aspolymers, plastics, medical devices, packaging,coatings, food and beverages, personal careproducts, consumer products, specialtychemicals, high-tech materials and more.

For more information, visit www.chemir.com

For more than 20 years, the Sologic team hasled innovations in root cause analysis training,consulting, software and investigation solutions.

Sologic helps organizations worldwide attainleading positions in a competitive globalmarket by achieving measurable results,

including: cost reduction, throughput gains,time savings, quality improvement, injuryreduction, improved regulatory compliance andreduction/elimination of day-to-day problems.

For more information, visit www.sologic.com

benefits

Chemir AnalyticalServices

Sologic

2501 Washington StreetMidland, MI 48642, USA

info@sologic.com

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