Recognise the symptom before changing settings
Describe what changes, where it first appears and whether it follows a product batch, packaging batch, filling head, lane, speed, temperature or time in the run. Typical observations include:
- the line never reaches the quoted rate
- short stops occur repeatedly
- operators constantly intervene
- individual machines run fast when isolated
Likely causes to separate
A symptom can have several unrelated causes. Treat the following as hypotheses to test rather than a list of settings to change at once.
- an unrecognised downstream bottleneck
- material feeding and replenishment interruptions
- excessive acceleration/deceleration or gaps between machines
- changeover settings not returned to centreline
- quality faults creating stops and rework
Check in this order
Check 1
Record a timed loss log by cause and machine.
Check 2
Calculate availability, performance and quality on one unit basis.
Check 3
Measure sustained accepted rate at every required operation.
Check 4
Check starvation and blocking states between machines.
Check 5
Compare current settings with the approved centreline.
Corrective actions to evaluate
After the cause is demonstrated, select the least disruptive correction that returns the process to a safe, repeatable and approved state.
- improve the actual constraint before raising upstream speed
- add controlled accumulation for short recoverable stops
- stabilise consumable and product supply
- standardise recipes and changeover settings
- remove recurring quality causes
Prevent the problem returning
- review loss Pareto charts regularly
- train operators to code stops consistently
- set line-control speeds as a balanced system
- use acceptance tests based on sustained output
Record evidence, not only the final setting
Capture the product and packaging batches, machine recipe, head or lane, speed, temperature, vessel level, symptom frequency, intervention and post-correction results. This creates a usable centreline and allows recurring loss to be prioritised through OEE or downtime analysis.
Common questions
What is the first check for packaging line running below expected speed?
Record a timed loss log by cause and machine.
What commonly causes packaging line running below expected speed?
Common causes include an unrecognised downstream bottleneck, material feeding and replenishment interruptions, excessive acceleration/deceleration or gaps between machines.
Should the machine be adjusted immediately?
Change one controlled variable at a time after the measurement method, product condition, packaging and safety state are confirmed.
When should production be stopped?
Stop and follow the site safe-isolation and escalation procedure when there is risk of injury, contamination, fire or explosion, uncontrolled product release, damaged guards, unsafe pressure or an unverified quality result.
What information should be recorded?
Record product and pack batch, recipe, machine settings, filling head or lane, time, temperature, speed, symptom, corrective action and the evidence that performance returned to the approved condition.