Hourly tests on a high speed line
Long time lurker, first time poster, i have been tasked with finding a solution on how to conduct hourly consecutive metal checks without stopping the line? The line runs at 120ppm and the customer does not want us to stop the line to conduct the test. :helpplease: .
Based on your metal detection method, would it be possible to run your hourly check for a set interval of time with no positive readings to show you are in control?
Mthazz: I had experience with this. I had a line running over 200ppm and had to ensure metal checks were performed without stopping as well. It's really about, depending on your process, can you do it? The product I was referring to was being packaged and i put the metal detectable stick in the packaging and ran it through with the product within the small gap the machine allowed. Of course it would shoot off each time, but you get use to it! There was always just enough space to put it through, and the machine had no issue detecting it up.
It's all about whether your able to depending on your machinery. But it can be done.
I will caution you against only 1/hour checks at that line speed.........that equals a possible 7200 units on hold between checks
Also.......why would you stop the line? The metal detector should be checked against normal operations..........otherwise how do you really know it working? There should be a bin where the bar plus the item fall into
Call the manufacturer and ask a technician to come to assist you understand how your metal detector functions
I would like to double up on Scampi's comments. IF you choose to perform checks every hour, your going to have a lot of product pass by. Be prepared to hold that much product in the event you have an issue with your metal detector. I would review your history to see if you usually have an issue or not. Something to consider.
Great point Scampi.
Good Luck!
On my point, If I validated properly the equipment and maintained as planned, would not that be so concern with the hourly check quantity, but agree that it will be always be the balance of how much you are willing to place on hold and how confident you are with your equipment. It is also better to do it while it is running, as what you "monitor" is that it function exactly as intended during normal operation. If there is an ample space (considering safety), you may want to insert there your test piece. Howver, it would be better to assist if somehow, the layout is presented.
Anyway, on 2nd thought, have you validated your equipment against successive contaminant (including the rejection device), if you are running 7200 pieces per hour then it would be 2pcs per second, the metal detector performance can be affected by the distance between next product and Xray will be dependent on the scanning length of the equipment. I would recommend if you haven't validated yet, that you do check your MD for successive contaminant.