Controlling Weight Loss of Volumetric Filling Machine: A Case Study of Coffee Mixed Powder

The objective of this study is to reduce the coffee mixed powder weight loss during filling into sticks by volumetric filling machine. Fishbone Diagram based on 4M analysis (i.e., Man, Machine, Material and Method) was applied to analyze the root causes and find solutions to reduce coffee mixed powder weight loss. This study was conducted as an action research in the practical situation by studying machine function of volumetric filling machine in the processing line and observing practices of operators. From brainstorming, the major root causes impacted coffee mixed powder weight loss were machine conditions with improper machine’s basic condition setting and weight adjustment by operators. The actions and experiments were executed by restoring basic conditions of volumetric filling machine and modifying some parts of equipment, e.g., design of agitator in hopper and design of weight scale. Visual controls and inspection standard for operators were also developed for control purposes. The improvement was carried out for three months consecutively. The powder weight loss from filling machine was successfully reduced from 0.38% to 0.24%, which was 36.84% improved.