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How to Increase Efficiencies by Removing Changeover
| Date post: | 23-Jan-2015 |
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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
✓
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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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