Cecil Rice Export: Bagging Process Weight Variation Analysis

$1.$ Introduction$/$System Description

Cecil Rice Export, a leading rice exporter headquartered in Alexandria, Egypt, has experienced significant growth in recent years. Upholding a commitment to continuous improvement and Lean principles, the company has expanded its rice bagging facility. This report delves into the bagging process, specifically focusing on weight variations in the final product. Maintaining consistent bag weight is crucial for Cecil Rice Export to ensure high$-$quality standards and customer satisfaction.

$1\mathrm{.}1$ System Description

The bagging process at Cecil Rice Export's Alexandria facility involves transferring bulk white rice from storage silos into individual $70-$pound grain bags. The bagged rice is then palletized and transported for export. The bagging system utilizes automated machinery with operator oversight.

$2.$ Problem Statement

Recent inconsistencies detected during the loading of palletized rice onto merchant ships have raised concerns about potential variations in bag weights during the bagging process. Deviations from the target weight can lead to:

Revenue Loss: Underweight bags result in financial discrepancies and potential contractual violations.

Customer Dissatisfaction: Inconsistent weight can damage customer trust and lead to order disputes.

Reputational Risk: Variations in weight can compromise Cecil Rice Export's image as a reliable and high$-$value supplier.

Addressing these concerns is essential to maintain the company's competitive edge and uphold its commitment to quality.

$3.$ Project Objectives

This project aims to achieve the following objectives:

Identify Root Causes: Conduct a thorough analysis of the bagging process to pinpoint factors contributing to weight variations.

Quality Control System: Develop and implement a robust quality control system to guarantee consistent bag weights throughout the production cycle.

Corrective Actions: Investigate and rectify any abnormalities detected during the loading process to prevent future occurrences.

$4.$ Scope of the Project

This project encompasses a comprehensive evaluation of the bagging process at Cecil Rice Export's Alexandria facility. The primary focus is on weight variations, and the analysis will:

Examine data from all operational shifts $($day and night$).$

Utilize detailed data collection procedures for a representative sample set.

Employ statistical analysis techniques to identify patterns and trends in weight variations.

Formulate actionable recommendations for process improvement.

$5.$ Contribution of the Project

This project delivers valuable insights into the bagging process, enabling Cecil Rice Export to:

Identify potential issues affecting product quality and consistency.

Enhance the overall efficiency of the bagging system.

Implement measures to ensure consistent and accurate bag weights.

Strengthen market position by solidifying a reputation for reliable, high$-$quality rice exports.

$6.$ Methodology

The project employed a data$-$driven approach to analyze the bagging process.

Data Collection:

Hourly samples of five bags were collected over three days, ensuring a representative dataset.

Shift$-$wise data was captured to discern potential variations across different work periods.

Data Analysis Techniques:

Control charts, specifically Individuals and Moving Range $($I$-$MR$)$ charts and X$-$bar and Range $($X$-$R$)$ charts, were utilized. These tools enabled a comprehensive examination of individual bag weights and subgroup averages, providing insights into process stability and potential sources of variation.

The detailed results of the data analysis will be presented in the following sections of this report.