MIX UP PREVENTION – BEST

PRACTICES
Mixed Packaging Impact & Cause

Mix-up Real Cases

Mix-up Prevention Approaches

Best practice of Mix-up Prevention Control Measures

Roadmap????
 Mixed Packaging Impact and Cause
Impact ：
Impact ： Cause
analysis ：
Regulation
Regulation
Product
Product Wrong printing
punishment
punishment plate 4%
recall
recall
Storage
and
trans-
portation Wrong
mgt issue
Consumer labelling
Consumer 22%
39%
complaint
complaint Brand
Brand
Defective
image
image products
mixed into
Line clearance
normal
failure
Labor and ones
31%
4%
financial
loss Production
efficiency

Mixed Packaging Impact and Cause

 Definition of MIX-UP
W F W
I G a
P st
 MIX-UP : Where two or more different products are mixed together e
due to various reasons somewhere in the supply chain.

 Types of MIX-UP :
• Mixing of similar products: Products similar in object appearance, package
appearance, new vs. old version mix, - Mix up ( Mis pack)
• Rejected/ Defective products are mixed into normal products.
• Trial samples are mixed into normal products.
• Standard samples are mixed into normal products.
• Identification confusion: The information of outer package is not matched with
objective material ( eg. mis-use of label for outer package) – Mis label
• Package mix-up: mis-use the outer package.
• Coding identification – wrong code identification – Mis Code
• Mixed at Storage and transportation process : Adjacent of staging areas, similarity of
material code/name, similarity of PO number, causing different products loaded on
the same pallet.
Mix-up case studies and Various mix-up occasions
 MIX-UP CASE STUDY
- MIX-UP IN ROLLINGMix-up
MATERIAL
case studies and Various mix-up occasions

Case: Two different SKUs are printed/jointed on the same roll

Two smilar looking material one with promo and second without
promo sent in same Invoice.

Pro
mo Non
Mat Promo
Mat

Cause: The remaining section of the last batch product on the machine is used to carry
the new batch to continue the smooth production, while it’s forgotten to cut off and
remove from the new batch which is different SKU product.
 MIX-UP CASE STUDY
- MIX-UP IN ROLLING MATERIAL

Cause: At joint similar looking two diff items codes laminates found

Mix-up case studies and Various mix-up occasions

Corrective actions:
1. Cut and remove the last batch
section & the “bridge” paper, retain
44188066 it with the production record and
verified by the line manager.
2. Pre information of similar looking
jobs but have slight difference.
3. While taking new roll verify the
item codes/ in case of doubt
consult with line manager / QC.
4. Display paper print of similar
looking jobs at each process
stage.
44068711
 MIX-UP CASE STUDY
- MIX-UP IN ROLLING MATERIAL
Cause: Promo and Non promo jobs are packed in same boxes.
Mix-up case studies and Various mix-up occasions

Corrective actions:
1. Separate store the similar looking
materials.
2. Danger sticker use with warning to
avoid mix up with similar looking
jobs.

3. Pre awareness
 MIX-UP CASE STUDY
- MIX-UP IN ROLLING MATERIAL
Cause: Similar looking jobs in same roll found at customer end
Mix-up case studies and Various mix-up occasions
 MIX-UP CASE STUDY
- MIX-UP IN ROLLING MATERIAL
Cause: Ptwo different jobs found packed in same Box.
Mix-up case studies and Various mix-up occasions

Pamper XL20 and L23 Mix Up

Found at customer end.
 Mix-up case study
- Mixed storage/stage of different products

Materials, WIP products, new

and old version materials are
staged together without clear
segregation or identification.
Disordered management poses
high risk to mix-up.

Mix-up case studies and Various mix-up occasions

Mix-up Prevention Approaches

FMEA function, demand ,product or process information

Failure Mode and failure modes for function un-achieved

Effects Analysis Consequence and effect of failure modes

Potential causes of failure modes

Actions to failure modes

Poka-yoka Corrective/Preventive actions to avoid repeating

(Fool-Proof) Note: FMEA: Failure Mode and Effects Analysis. Tool to identify
potential modes of failure, the likelihood that they will occur and
Mix-up Prevention Approaches the severity of the consequences.
 FMEA– ANALYSIS PROCESS

What’s the
consequence
What can be
Step 1 ?
done?
• Design alternate
How on process
severity it alternation
What are the is? • Special control
function, How often it
features and happens? • Change the
requirements?
standard process
What’s the or guidance
Step 2 cause?

What has been

done?
Why
failed? How good the What’s the result?
detection
How to mechanism
prevent and is?
Step 3 detect?

Mix-up Prevention Approaches

 Mix-up Prevention Main Control Points
Main Control Points
Artwork design and supplier induction
Preparation for package printing
Production process control
1.printing
4.on-line quality check equipment
5.adhesiving and packing
End of production
Storage
Transportation
Control Measures
Artwork design and confirm, to be easily identified among different SKU products
Refer job file / approved art work / FDG number on cylinder or plate as applicable
Avoid producing similar materials in the same period when making production plan
Ensure the good line clearance to remove irrelevant materials in work area
Choose the correct printing Cylinder/plates.
Choose the correct material, printing ink, surface oil, etc. for printing
Prepare the designated pallets to store the product - one job on one pallet and
identification sticker for similar looking jobs
Prior information to all for similar looking jobs
Prepare process record and label (e. g. Danger Sticker )
Segregate production area, staging area, holding area, rework area, finished product
storage area, etc.
Set up critical control points for line clearance
Start-up check before the mass production against standard sample - FSA
Ensure the functioning and verification of on-line quality check equipment; prevent the
rejected products mixed into normal product.
Check the color mark for compliance; one product one line
Line clearance including the identified critical points, WIP, standard samples, remaining
products, etc.
Product identification in finished product area, segregation of waste/non-conformance
product area
Ensure the information compliance among inventory physical check, record and labelling.
Ensure the effective physical isolation of different products and non-conformity products
Choose the correct product to load
Physically isolate different types of product to avoid mix-up during transportation
Ensure different products and pallets are shrink wrapped and have clear & correct tags for
easy identification
 Process management— fool-proof ： color visual
management
for products in the same size and similar printing
 use labels, packing ropes, etc. in different colors to distinguish
 use containers in different colors to distinguish
 We do color coding in P & G pouch jobs

Best practice in mix-up prevention approach 17

 PROCESS MANAGEMENT— FOOL-PROOF ：
BAR CODE SCANNING CHECK
before after

Problems before improvement ： Effects after improvement ：

Confirm mainly by operator visual checking external Print bar codes labels on all roll cores and external case
box labels and product names and standards on label automatically printed after checked and counted
certificates when loading easily results in mix-up. by scanning one by one when packing. In case wrong
label scanned, system would alert users.

Best practice and examples of mix-up prevention

LINE CLEARANCE CRITICAL POINTS FOR MIX-UP PREVENTION

Line clearance before

High-risk points
and after production

Amulya Rs-5, printing has been done with

two address (sabarkantha and
Banaskantha), plz follow alc to avoid
mixup.
w/o detail- Banaskantha-291080360
sabarkantha - 291080362

Information on roll to avoid mix-up in

similar looking jobs

Care to be taken by operating team during

next processing.

Best practice in mix-up prevention approach

 LINE CLEARANCE VERIFICATION—CCP “CRITICAL
CLEARANCE POINT” AND CHECKLIST
Line Clearance Checklist- Printing

Critical Clearance Point

At Uflex – 3 CCPs
Drying temp at Solvent based Printing
Drying temp at Solvent based Lamination
Blade at Slitting.
Best practice in mix-up prevention approach
LINE CLEARANCE VERIFICATION—CCP “CRITICAL
CLEARANCE POINT” AND CHECKLIST
Line Clearance Checklist- Lamination

Best practice in mix-up prevention approach

 3M – P & G GUIDELINES
 Mis-label, Mis-Pack, Mis-
Code
 1. Overall
 2. Material Receiving, Storage & Release
Control
 3. Material Staging Control
 4. Changeover, Line clearance and Start Up
Control
 5. Ongoing Making and Packing Operations
Control
 6. Labeling and Coding Control
 7. Leftover Material & Products Control
 8. Rework Control
 9. Change Management Control
Left over material on core – core with left
over material on core end used at rewind
of machine – Printing & lamination
J & J CHANGED TO JNTL
J & J CHANGED TO JNTL
Win-Win!