Engineering at its Best

Got a funny that's clean or even an accidental funny. Let's all get a good laugh because it's healthy.

Moderator: Team Cub

Forum rules
Keep it clean (we have youngsters here) and leave the politics and religious jokes for some other forum :)

Engineering at its Best

Postby lazyuniondriver » Wed Jan 30, 2013 10:45 am

A consumer product manufacturing and packaging company was fielding an excessive number of complaints about empty cartons without product being shipped to the stores.

Occasionally the fully automated packaging line would fail to fill a carton which was then sealed, stacked, wrapped and shipped without detection.

The company commissioned an engineering firm to ferret out and eliminate the problem at the final expense of over one hundred thousand dollars.

After the 3 month study of the packaging line and the subsequent generation of reports, the manufacturing company sourced a material handling firm to build the solution the engineering firm recommended.

Due to the complexity of the packaging process, the engineers suggested it would be more cost effective to catch the problem after the fact instead of eliminating the actual intricate carton filling problem at its source.

An automatic weight scale system was installed on the belt line after the cartons were filled and sealed but before the cartons were palletized and wrapped. When a carton crossed the scale weighing less than the target weight of a filled carton, the belt would stop and a pneumatically operated arm would push the empty carton off the scale into a bin. Per OSHA regulations, before the belt restarted, a brief alarm would sound signaling the line was again starting into motion.
The modification to the conveyor belt worked flawlessly and the CEO was pleased even though quite a bit was spent, the customer complaints immediately dropped off.

The packaging line was completely computerized and monitored so packaging reports could be generated upon request. The CEO studied the report from the first month the scale and carton rejection device was integrated into the packaging line to see how fast the huge expenditure would be recouped. He was shocked to find what seemed to be an error in reporting.

According to the report, the scale device's first day in operation caught about a half dozen empties an hour on their way to be palletized, consistent with the amount of prior complaints generated from the stores.

From the second day forward, the scale had rejected 0 empties. Knowing this was impossible, he directed maintenance to inspect the sensors and to look for a loose plug end or damaged cable.

The next day the CEO pulled another report after maintenance assured him everything was operational. The previous 24 hours was no different. Not understanding how this could be happening, the CEO went out into the plant to look for himself.

The CEO looked at the scale, looked at the wiring, looked at and wiggled the plugs but saw nothing out of the ordinary. He assumed it must be an internal sensor or a photo cell that must be causing the problem.

Upon returning to the office, he noticed about 10 feet before the new rejection station, someone had placed a table with a desk fan on it blowing across the belt. He summoned the closest employee asking what the fan was supposed to be cooling.

The employee stated someone from maintenance put it there to blow the empty boxes off the line so the annoying alarm buzzer wouldn't keep going off.
"HAVE ALL YOUR DELIVERIES MADE BY UNION DRIVERS"
Image
lazyuniondriver
Cub Star!!
Cub Star!!
 
Posts: 438
Joined: Tue Aug 07, 2012 1:37 am
Location: Southern Suburbs of Cleveland, Ohio
Zip Code: 44134
Tractors Owned: 1949 & 1951 Farmall Cubs

Several Snapper Garden Tractors
Circle of Safety Award
Circle of Safety: Y

Re: Engineering at its Best

Postby Bill Hudson » Wed Jan 30, 2013 11:41 am

:bellylaugh: :bellylaugh:
"The probability of life originating from accident is comparable to the probability of the unabridged dictionary resulting from an explosion in a printing shop." Edwin Conklin, biologist
Bill Hudson
Team Cub
Team Cub
 
Posts: 6243
Joined: Wed Jul 26, 2006 10:50 am
Location: OH, Madison
Zip Code: 44057
Tractors Owned: :
57 F-Cub
64 Lo-Boy
68 Lo-Boy
52 F-Cub
Circle of Safety Award
Circle of Safety: Y

Re: Engineering at its Best

Postby John *.?-!.* cub owner » Wed Jan 30, 2013 1:42 pm

difference between engineers and technicians.
"The Constitution is not an instrument for the government
to restrain the people, it is an instrument for the people to restrain the
government lest it come to dominate our lives and interests." Patrick Henry
User avatar
John *.?-!.* cub owner
Team Cub Guide
Team Cub Guide
 
Posts: 19101
Joined: Sun Feb 02, 2003 2:09 pm
Location: Mo, Potosi
Zip Code: 63664
Tractors Owned: 47, 48, 49 cub plus Wagner loader & other attachments. 41 Farmall H.

Re: Engineering at its Best

Postby Eugene » Wed Jan 30, 2013 2:56 pm

Sounds like the company of my last employment.
I have an excuse. CRS.
Eugene
Team Cub Mentor
Team Cub Mentor
 
Posts: 12125
Joined: Fri Jul 02, 2004 9:52 pm
Location: Mo. Linn
Zip Code: 65051
Circle of Safety Award
Circle of Safety: Y

Re: Engineering at its Best

Postby dgrapes59 » Wed Jan 30, 2013 4:09 pm

I was in a meeting yesterday and someone was telling a similar story, he referred to them as "Tweakers". I had to forward it to several people at work that can relate to similar things going on in some of our plants.

Thanks for sharing,
David
User avatar
dgrapes59
501 Club
501 Club
 
Posts: 2609
Joined: Sun Jul 13, 2008 10:05 pm
Location: OH, Liberty Township (45044) (southwest OH)
Zip Code: 45044
Tractors Owned: 1951 Cub
1955 Loboy
a few plows, mowers, blades & such
Several '61 CC Originals, CC Narrow Frames- 70 & 100's, 71, Couple 102's & 122's, 72, 124, 73, various CC options & implements #2 Trailer, 1963 Springfield
Circle of Safety Award
Circle of Safety: Y

Re: Engineering at its Best

Postby beaconlight » Wed Jan 30, 2013 4:15 pm

KISS Keep it simple stupid.
Bill

"Life's tough.It's even tougher if you're stupid."
- John Wayne

" We hang petty thieves and appoint the great ones to public office."
- Aesop
User avatar
beaconlight
Cub Pro
Cub Pro
 
Posts: 7698
Joined: Thu Aug 19, 2004 2:31 pm
Location: NY Staten Island & Franklin
Zip Code: 10314


Return to Cubber's say the funniest things

Who is online

Users browsing this forum: No registered users and 1 guest