How to Increase Efficiencies byRemoving Changeover

Agenda

Product handling considerations

Live Q & A breaks

Mistakes to avoid when minimizing changeover

Controls and logic requirements

Conveyor systems and equipment options

Line layout recommendations and examples

Cost comparisons and payback

✓

7

6

5

4

3

2

1

Agenda

Mistakes to avoid when minimizing changeover

Live Q & A breaks

Conveyor systems and equipment options

Controls and logic requirements

Product handling considerations

Line layout recommendations and examples

Cost comparisons and payback

✓

7

6

5

4

3

2

1

Agenda

Mistakes to avoid when minimizing changeover

Live Q & A breaks

Product handling considerations

Controls and logic requirements

Conveyor systems and equipment options

Line layout recommendations and examples

Cost comparisons and payback

✓

7

6

5

4

3

2

1

Agenda

Mistakes to avoid when minimizing changeover

Live Q & A breaks

Line layout recommendations and examples

Controls and logic requirements

Conveyor systems and equipment options

Product handling considerations

Cost comparisons and payback

✓

7

6

5

4

3

2

1

Agenda

Mistakes to avoid when minimizing changeover

Live Q & A breaks

Controls and logic requirements

Product handling considerations

Conveyor systems and equipment options

Line layout recommendations and examples

Cost comparisons and payback

✓

7

6

5

4

3

2

1

Agenda

Mistakes to avoid when minimizing changeover

Live Q & A breaks

Cost comparisons and payback

Product handling considerations

Conveyor systems and equipment options

Line layout recommendations and examples

Controls and logic requirements

✓

7

6

5

4

3

2

1

Agenda

Mistakes to avoid when minimizing changeover

Controls and logic requirements

Live Q & A breaks

Product handling considerations

Conveyor systems and equipment options

Line layout recommendations and examples

Cost comparisons and payback

✓ 7

6

5

4

3

2

1

Avoid Accumulation

Through Turns

Failure toConsiderOperating

Costs

Combining SpeedWith

Product Manipulation

Extreme Diversity OfProducts

Accumulation Through Turns

Mistakes to Avoid

Failure toConsiderOperating

Costs

Combining SpeedWith

Product Manipulation

Extreme Diversity OfProducts

Extreme Diversity of Products

Mistakes to AvoidExcessiveProduct

Crowding

Failure toConsiderOperating

Costs

Combining Speed With

Product Manipulation

Extreme Diversity OfProducts

Combining High Speed With Manipulation

Mistakes to AvoidExcessiveProduct

Crowding

Failure toConsiderOperating

Costs

Combining SpeedWith

Product Manipulation

Extreme Diversity OfProducts

Failure to Consider Operating Costs

Mistakes to AvoidExcessiveProduct

Crowding

Conveying Equipment

Vertical Conveyor Lifts

Best Uses

Carton Handling

Case Handling

Bundle Handling

Speeds 30 CPM

Product weights less than 40 lbs.

Vertical Conveyors

Conveying Equipment

Drum Spiral Conveyors Drum Spiral

Conveying Equipment

Drum Spiral Conveyors

Best Uses

Product Flexibility

Product Diversity

High Capacity

Mass Flow

Higher Rate Applications

Multiple product orientation

Product stability

Conveying Equipment

Serpentine Accumulators Serpentine Accumulators

Conveying Equipment

Serpentine Accumulators

Best Uses

Product that can’t handle back pressure

First-In, First-Out

Accumulates during short down-times

Conveying Equipment

Reflow Accumulating Table

Conveying Equipment

Reflow Accumulating Table

Best Uses

Round product shapes

Small footprint

Low backpressure accumulation

Minimal controls required

Accumulation Tables

Conveying Equipment

Bi-Directional Table Bi-Directional Table

Conveying Equipment

Bi-Directional Table

Best Uses

Round Containers

Various Sizes without Rail Changes

Off line storage

Conveying Equipment

Nercon Knowledge Center Media Center

Conveying Equipment

Single Filer / Combining Conveyor

Best Uses

Product versatility – tapered containers, non-round shapes

Single Filing without Changeover

Mass Flow

Product Alignment

Pressureless Combiner

Conveying Equipment

ARB Technology

Conveying Equipment

ARB Technology

Best Uses

Handles various types of products and shapes

High Capacity / Rate

Weight variety

Product variation

BEFORE

AFTER

Conveying Equipment

Live Roller Metering /Merging Conveyor

Live Roller Metering/Merging Conveyor

Conveying Equipment

Live Roller Metering/Merging Conveyor

Best Uses

• Low profile products

• Hard to handle packages

• No backpressure

• Multi-lane merging

BEFORE

AFTER

POLL QUESTION:What do you consider a minimum acceptable payback for capital purchase projects?

1. 6 months or less2. 6 to 12 months3. 1 to 2 years4. Over 2 years

BEFORE: A system example

BEFORE: A system example

BUMP TURNBump Turns

BEFORE: A system example

CLAMP

BEFORE: A system example

STAR WHEEL UPENDERStar Wheel Upender

After: A system example

After: A system example

WIDE EDGE LEADING PRODUCT FLOW

After: A system example

DUAL CHAIN CASE TURNERS

After: A system example

STAR WHEEL – on Sliding Carraige

After: A system example

END – OF – LINE AUTOMATION

Manual Pack Station

Redesigned for Robotic Pick-up.

Devices

Dual Lane Rotator Star-wheel Upender

Product Handling Characteristics

Oval ContainersRound Containers Cartons

Cases Pouches

Round Containers

• Single dimension

• No orientation

• Easier to group similar sizes in guiderails

Round Containers

Oval Containers

• Orientation

• Tapered containers

• Traveling on lids/caps

• Puck transportation to eliminate changeover (same pucks)

Oval Containers

Cartons

• Challenges traveling hard way

• Orientation issues

• Needs of assembly line equipment

• Top load/End load/Side load

• Length vs Width

Easy Way Vs. the Hard Way

Easy Way Hard Way

Cases

• Typically sizes on case erectors are close in dimensional sizes

• Elevating equipment should handle multiple sizes without changeover

• Justification can help eliminate changeover

Flexible Packages

• Watch out for flaps & seals

• Accumulation causes product shingling and or damage

• Can cause jams and issues with interface equipment

• Similar pouches can be looked at for eliminating change over

INPUT DATA8 Hrs / Day, 250 Days / YearEQUIPMENT COST: $60,000LABOR SAVED: 15 Min / DayLABOR RATE: $30 / HrUNIT PROFIT: $0.25 / UnitTHROUGHPUT: 40 / Min.FUTURE SALES: 3% / Year

BEFORE AFTER

ARB System Example

UPTIME / LABOR$39,500 / Year1.5 Years

FUTURE SALES$36,000 / Year1.7 Years

Best Case .80Worst Case 1.46

INPUT DATA8 Hrs / Day, 250 Days / YearEQUIPMENT COST: $36,000LABOR SAVED: 30 Min/dayLABOR RATE: $30/ Hr.UNIT PROFIT: $0.25/ UnitTHROUGHPUT: 16 / Min.FUTURE SALES: 3% / Year

BEFORE AFTER

Live Roller Merge Example

UPTIME$34,312.001.05 Years

FUTURE SALES$14,670.002.45 Years

Best Case 0.73Worst Case 1.45

ROI

UPTIMEFUTURESALES

How to Increase Line Efficiency byRemoving Changeover

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