Solve the problem stopping your production.

Start with the symptom and collect the next useful evidence

Choose the first place the problem becomes visible, then record the product, pack and operating condition. The routes below help organise an investigation; use approved procedures and competent support where checks involve machine access or safety.

Fill quantities vary between packs

Separate a changing product condition from a problem at one filling position. Record the affected recipe, dose, temperature, head or nozzle and whether the fault appears after a pause or refill. Confirm how quantity is measured before changing settings. Continue with the filling-variation route to compare the observations.

The line runs but finished output is low

Count accepted packs at a defined line exit and record stops, reduced speed and rejects over the same period. Note which stations are blocked by downstream equipment or starved of incoming product. Avoid selecting a faster machine from a queue alone; use the bottleneck guide to examine what caused the lost output.

Caps leak or engage incorrectly

Keep affected and acceptable bottle-and-closure samples from the same run. Identify whether the issue starts with cap presentation, seating, thread engagement or a later check. Record component changes and the test method. A torque value without its measurement conditions is not enough to explain a leaking pack.

Labels wrinkle, move or lift

Separate label position from adhesion. Compare container presentation, label supply and the point at which the defect first appears. For lifting edges, record surface condition and elapsed time after application as well as the initial appearance. Use the relevant problem route so the investigation stays focused on the observed failure.

Pouch or pack seals are inconsistent

Retain the product, packaging reference, settings and examples of accepted and failed packs. Note contamination in the seal area and whether the problem follows a stop, refill or material change. Agree the quality test before interpreting appearance; a neat-looking seal alone does not prove every required integrity property.

A complete line needs a clearer brief

Map the process from incoming product and packaging to released finished packs. Record each manual transfer, repeated interruption and required quality decision. Use a controlled requirement and representative sample trial to compare possible improvements. Keep the evidence from the current process so any later result can be judged on the same basis.

Continue with the relevant guidance

• Investigate inconsistent filling
• Find line-output losses
• Investigate closure faults
• Check label position
• Check label adhesion
• Explore sealing checks
• Record a controlled production trial