The manufacturing lot traveler was pulled and reviewed for lot 481293.The product was produced in may of 2014.All information on the traveler indicates that the product was produced within specifications.There was an engineering change orders but it was for a gasket change on form fill seal which would be of a unrelated piece of equipment.All pull tests (which ensure proper bond between the string and pattie) were reviewed and found to be within acceptable limits.The minimum pull strength specification is 2.0 lb and this lot, but the alert level is 3 lbs.All the pull tests ranged from 3.4 lbs to 7 lbs.Therefore root cause could not be determined.It looks like the string wasn't presence when the welder came down to weld the components together.All the operators are trained to inspect all the patties and wrap them onto the card.It seems that the operator missed this reject and because there was ten patties with string the operator fulfilled the card requirement of having ten strings present, but with eleven patties.The machine always counts out 10 patties so the operator must of missed the first check pattie that the machine makes to start the process.The scenario above is a very rare occurrence.We have seen very few complaints for this particular failure mode.We will continue to monitor customer complaints to ensure this is not a developing trend which will require corrective action.At the present time this complaint is considered closed.
|