Ice Cream Line Waste Reduction

We were engaged by an ice cream facility to reduce the product waste and increase the line efficiency of a recently installed ice cream bar line. Through a structured continuous improvement process, we identified the reliability of certain proximity sensors were causing product breakages and jam-ups.

A root cause analysis was performed, which identified the type of proximity sensors being susceptible to reflection from the conveyor belt. An alternative sensor type was identified, trialled, and implemented across six product lanes, resulting in a significant reduction in product waste and line stoppages.