Transforming the Nasonex Packaging line into a High-Speed, High-Output Operation

PACKAGING OPPERATIONS, SINGAPORE, IPT WEST TABLET FACILITY

This PowerPoint presentation will give you an idea of all that’s been changing with the Nasonex Packaging line here at IPT West, Singapore. One by one we evaluated each machine in the line, studied what problems each machine had, and determined the root cause! In almost every case I and my team were able to correct the issues with modifications made in such a way as not to change the way the Equipment functions, meaning no wiring or program changes! What you will see is that I simply Adapted the Equipment to work well with all our component's & where possible made all the difficult adjustment areas easy to adjust…….This means less time to change-over when switching between production runs.

• Replace the current Intermittent Cartoner with a Modern Continuous high speed Cartoner

• Adapt the F-350 Crimping Machine so we can run the USA product (Small Bottle).

• Evaluate Which Machines have the most trouble and why.

• Identify trouble points in the line and correct the Problems.

• Inventory and increase the Parts we keep in Stock.

• Inventory, increase & Secure the Parts we keep at the Nasonex line.

• Inventory Tools and ensure the Technicians have all the right tools to support continuous line operations.

• Procure Specialty Tools i.e.: Snake Camera, High Speed Camera, Bearing Extraction & Installation Kit, Drummel Diamond High Speed File, Special Drills & Bits.

• Purchase & make accessible all Hardware needed for the Line, Nuts & Bolts, Washers, Spacers, Clips, and so on.

• Re-write PM’s so they are effective and eliminate down time.

• Develop and implement a Maintenance check list to be Preformed between Batches.

PRIORITIES FIRST

Too be sure we have many more priorities than can be listed on a PowerPoint slide, in fact the list is almost endless…!

CP-18 CASE PACKING MICHINE &

* We have changed the PM plan to

include a TPM program.

* Created Job-Aids for smooth &

efficient product change-over.

* Intensive training for Trouble-

shooting & maintaining this

machine.

MS-300 STRECH-BANDING MACHINE

The CP-18 Case packer is the work horse on our line, with a great many moving, wearable parts! This Machine works quite well, however with the increased production volumes , combined with the smaller box size for the USA Product, the machine speed will run 3 to 5 times faster!

MS-300 STRATCH-BANDING MACHINEWe ‘ve taken advantage of a

long overdue Up-grade for the

sealing unit on our Stretch

Bender. This along with a

improved PM Plan & TPM

replacement program will allow

us to run the equipment at full

capacity .

One issue I was informed of when I met with IMA Representatives in late 2012, is that Singapore since the start up of the Nasonex Packaging line does not take advantage of any upgrades the manufacture has offered! This is a mistake, equipment manufactures do not make these changes for no reason. In most cases they improve the way the equipment operates. It is in the manufacture’s best interest to provide the most productive, relievable machines as possible if they hope to sell you equipment in the future?

OUR PREVIOUS CARTONER The IMA Flexa Intermittent Cartoner

This Intermittent Cartoner served the line well for eight years, however it can only function reasonably well when run at lower speeds. For the most part this technology is obsolete i.e.: The Pushing Product arm system, the Product conveyor & GUK Leaflet Folder. The entire machine requires constant maintenance and even then still breaks down unexpectedly causing Line stoppages & Slow downs!

Uhlmann C 2205 Cartonator Our New Cartoner

The Uhlmann C 2205 Cartonator is a superb Machine, it runs smoothly & efficiently at low or high speeds! It is state of the art technology and will use Pre-folded leaflets……

Up until now it has always been very

difficult to Adjust the Star-wheel Inlet &

Outlet of this machine, do to the fact that

the center Plate was one solid Piece!

That all changed in April 2013 when

Engineering Tech “Siva Kumar” devised a

way to easily make this adjustment.

“IMA” MS-300 LABELLING MACHINE

Siva realized the what made this Section of the Machine so difficult to adjust was the fact that the center Plate between the inlet & outlet Star-wheels was one Piece, so if you adjusted one side it effected the other side. So he decided to split the center Plate into two separate sections, this innovation gives us the ability to adjust each side independently. We have since discovered that we have far less rejects if the Inlet Star-wheel is set-up to a tight fit.

F-572 PLUGGING &CAPING MACHINETheir were a few problems with this

machine switching/running different

products, however nothing we couldn’t

solve with a few innovative ideas!

We enhanced the way the dust cap is

delivered to the Star-wheel and made the

process visible to aid adjustment.

Finally, we enhanced the Star-wheel to

better fit all our Products.

I observed after removing 20mm of the Dust-cap Dispensing head, two things were responsible for impeding this process….. !1. Many of the Dust-caps were not turning to the proper orientation before entering the Star-wheel, they typically would be crushed by the Star-wheel & jam up the system! • This problem has been solved by the addition of a Stainless Steel Wedge, which ensures that all Dust-caps are in the proper orientation before entering the Star-wheel. !2. All of the Dust-caps were being “Under-Cut” by the Star-wheel as they are taken away from the Dispensing head. By this I mean the Dust-caps were being knocked over from the bottom and Jamming the system…. • I solved this Problem by increasing the height of the Star-wheel to 30mm there by encompassing 65% of the Dust-cap with the Star-wheel as it guides the Dust-cap through the dispensing head……. An example of this can be see on the following slide.

IMPROVING THE DISPENSING UNIT

It is very difficult to adjust a piece of equipment you cannot see or if you cant see what's happening. To the left you see our old dispensing unit, from no angle can you see what is going on inside this unit! To the right is our improved version, to discover what was going on inside the Unit we cut away 20mm of the front of the face. This showed us what was taking place inside, and allowed us to make the appropriate improvements! Notice the Stainless steel wedge to the far right of the unit, this wedge successfully turns the dust cap to the correct orientation to be picked up by the Star-wheel…..

Made More Reliable & Less Costly to Operate!

O.Z.A.F UNSCRAMBLING UNITS

O.Z.A.F

AC-1500

UNSCRAMBLER FEEDING SYSTEM

The following slides will show how we were able to vastly improve the performance of the OZAF: AC-1500 Unscrambler! Once again this was accomplished without changing in any way how the equipment functions, “No program or wiring changes were needed”.

Before 100kg After 55kg

Lighten the load

What you see before you is the Under Plate for the Selection Disk, this plate weighs 100kg. Because of the awkward position it sits in it took 4 men to safely remove this plate from the Machine! Not to mention the fact that reducing the overall weight has eliminated costly break downs, it is now much easier & Safer to work with this Unit during annual PM Maintenance. Here, two things need to be carefully adhered to too properly reduce the weight of this disc! 1

st , we had to maintain the Balance of the Plate. 2

nd , we also had to ensure enough space was left for the support wheels two revolve around the Plate “as you can see by the red arrows” !

One of Eight selection disks One of two center pieces

Maintaining Balance

What you see here are Pieces of the AC-1500 Feeding System called the “Selection Disk”, there are 8 outer and 2 center pieces. The main challenge of this task is to ensure the same amount of material is removed from every piece, so as to maintain balance throughout the Disk as it rotates. Another challenge was to maintain the same height of the selection disk so the way the machine functions will not have to change. By beveling out from the underside of all the Selection Disk Units, we were able to reduce the overall weight by 40%........... Thereby greatly reducing the pressure, Stress & torque on the Drive Shaft, Gearbox, and Motor……..

Panasonic motor & gear box The OZAF AC-1500 Feeder

Too much of a job for a little drive unit

Yes, this tiny motor & Drive unit was pushing all that weight! In the Past we experienced many break downs on both our Unscramblers, what we have experienced is the Drive shaft, Gear box, or motor fails on average 2-3 times a year. Not to mention the Poor running performance experienced, prior to the event. Each time this occurs we are forced to do major disassembly at the price of 4 to 6 or more hours in down-time, and replacement parts are very costly and there is a delivery time of 2-3 months……

Reduced weight = Reduced STRESS

Due to the excessive weight of the 1 inch thick solid Metal mounting Plate and the 2.5 inch thick solid Teflon surface of our two Unscramblers, we were seeing (on average two times per year per Unit) unreasonable brake-downs from broken motor shafts, burned out motors, and bad gearboxes. The lost time from any of these conditions is 4-6 hours and often exceeded eight (8) hours or more if parts were not available.

The Pervious Photos show how we corrected this problem, without changing in any way the functionality of the Machine!

They say a Picture is worth a thousand words………..

RAMSEY 9000 HIGHSPEED CHECKWEIGHING SYS ‘Primary Side’This Unit historically has been a

major source of production

slow-downs & line stoppage’s

since start-up, mainly due to the

Input Scroll feeding system &

the Output system!

The original out-feed system on the Ramsey 9000 Check weighing unit was a complete disaster, I cant think of one day since I've been in Singapore that this system hasn't either broken down or given us major trouble and slowed the production down! The manufacture offered to help us improve this unit for the sum of $60,000 dollars! I declined! As you will see, our own improvements are better, simpler and require little to no Maintenance. Best of all, the cost was only $3,800………

RAMSEY 9000 INFEED SCROLL SYSTEM

What you see here is the old In-feed Scroll system for the Ramsey 9000 Check weighing Unit. Basically the theory of operation is good. The main trouble is the original scroll! It is not a proper fit for our product, so the system often crashes & is difficult to adjust.

Basically this is not a bad design, its main trouble is the original scroll! It is not a proper fit for our product so the system often crashes & is difficult to adjust. Also for the most part Ramsey used very low quality components, under sized bearings, and cheap aluminum drive gears. To Improve this Unit we replaced the scroll with one from our own IMA Machine, made specifically for our product, we redesigned the front end to house heavier bearings and had the gears made from steel so they can hold up to continuous long term service.

A PLC Driven Star wheel Feeder! “Suggested by local contractor” $35,000 SG

My modification of the existing Scroll feeder features, double ball bearings on each side of the Scroll & a chain drive system…. No more broken Belts…! Costs: $2,100 SG

KEEPING IT SIMPLE

On the left you see the in feed control system suggested by the manufacture “Thermo Ramsey” , notice how many sensors are on this system! It is even controlled by its own PLC…. All this is unnecessary and it will just be more to maintain! To improve this Unit we replaced the scroll with one from our IMA Machine, made specifically for our product, we redesigned the front end to house heavier bearings and had the gears made from steel so they can hold up to continuous long term service.

RAMSEY 9000 OUTFEED SYSTEM

Keeping it Simple

On the left is the original out-feed system, notice how the red belt on the left is turning black! That is one reason we always had to stop and change these belts “ it eventually would get on the Product”. Take note that the New & Improved system presented to us by a local contractor, is not only exactly the same as our old system, but it now has two Belts…! Compare that too our design in the next slide, which no moving parts and will never require any maintenance…….

EASY OUTKEEPING IT SIMPLE

My design is simple,

no wearable moving

Parts, no Maintenance

cost!

Cost: $800 SG

The old system was costing us about 20 to 30 thousand yearly in repairs, not including all the lost Production time! Our new system as you can see has only one moving part, ”A Piston Blocking Gate” which will last years. This new system has been in service since March 2013, to date we have had zero problems or production slow downs, it has never even had to be adjusted…….!

Our Old System The New System

HIT OR MISS

If you look closely at the Photo on the right you can see we add a guide rail system on both sides, which guides the bottle all the way to the scale!

From Start To Finish

ON TARGET

Our New guide rail system runs the entire length of the in feed conveyor, delivering the bottle on target every time….!

Speedy Replacement Simplicity

REPLACING PARTS MADE FAST & SIMPLE

Making equipment interchangeable will enable us to quickly get the line back into operation in the event of equipment brake down! In the past when this Scroll feeder would brake down, operators would stop the line and call for an engineering tech. The Engineering tech would repair the unit “in place” right at the line, losing an hour or more in production time! Now we will simply unplug the unit, Pop in the spare and we are back in production! This takes less then five minutes. The Engineering tech will repair it “off line”……..

SUMMERY CONCLUSION

With a few simple ingenious design changes/modifications, I was able to prepare the Thermo Ramsey 9000 plus High-speed check weighing system to perform at the higher production levels which will be required to support our new Uhlmann C 2205 Cartonator.

Modifying the in feed scroll feeder: $2,100 SG

Modifying the out feed cross over: $800 SG

Enhancing the “Thermo Ramsey Primary Check weighing system” for under $3,000 SG, instead of $55 to 60,000… PRICELESS…..!

Also, once again you will see that I in no way changed how the equipment functions, I simply improved how it works and made it easy to work with…….!

EFFICENT CRIMPINGFast, Stable, Reliable!

The following slides will show in detail how I and my team made Improvements on every section of this machine to improve its performance & reliability, while adapting it to successfully crimp the smaller 10 & 7.5 gm. Bottles! You will see that we were able to accomplish this task using the same Crimp-head, eliminating the need for equipment changeover between products. You will also see how I adapted the Crimping device to successfully crimp all our products at a fraction of the costs paid to the equipment manufacture for there unsuccessful attempt.

F-350 ROTARY CLOSING MACHINENumerous Improvements have

been made on this Machine.

Starting with the Crimping-

heads, the Short hose sensor,

Missing hose sensor, SVIM

Camera system, the Pump

Gripper & the Pump

Dispensing-head!

THE PUMP DISPENSING HEADAdjusting this unit to run smoothly, without

stoppages & break downs has proven very difficult

for the operations personnel.

1. You cannot see the Pump as its being dispensed.

2. The Dispensing arm continuously seizes up

during operations.

3. The Pump gripping arm occasionally crashes

into the Dispensing Unit, causing enormous

Damage resulting in lengthy down time.

The Old Device was one big heavy piece of Stainless Steel. The bracket for the stopping piston was mounted in the front of the device, preventing the Operator from viewing the Pump as it is past to the Pump Gripping Carousel “as you can clearly see in this Photo” Thus making it very difficult for a technician to adjust……

The original Pump Dispenser Our Improved Pump Dispenser

TO SEE OR NOT TO SEE….?

As you can see the difference in the two devices are remarkable! I moved that hefty bracket to the back of the unit, installed two sealed precision bearings for the dispensing arm, and created a easy break away front end piece to prevent damage in the event of a crash! To date, All the feed back from the Operators is that they really like being able to see what they are Adjusting…… and it makes it easier for them to adjust the Pump stopping Piston arm also. Once again as you will notice, absolutely nothing has changed with respect to how this device functions! We only made it function better……. This same new style dispensing unit has been on the Crimping machine since JAN 2013 “6 months”, where by in the past we would have to change parts 1-2 times a month….

IMPROVED PUMP DISPENSING UNIT1. Most noticeably you can now see the Pump

being dispensed.

2. Two ball bearings have been added to the

dispensing arm shaft so as to facilitate smooth

continuous movement without seizing up.

3. The front of the Unit has been designed to

“Break Away” in the event of a crash! It has been

cut away and reattached using Nylon or

Aluminum screws.

If you look closely you can see the Breakaway feature added to Unit. Along with this Breakaway guide, I have Improved the Crash Prevention System associated with the Pump Gripping Carousel. This greatly reduces the chance of a crash, however if and when they do happen the breakaway feature will prevent major damage! “it has already saved us with a crash we had shortly after its Installation” This unit has continuously been a major source of line stoppages and Production slow downs in the Past, therefore resolving the issues associated with it is a must if we are to increase our production levels! The time wasted adjusting this unit to run smoothly and continuously has been never ending. The down time associated with the crashes between the Pump Gripper & Dispensing head have Easley exceeded ¾ of a shift. Three Improvements! 1. Moving the blocking piston mounting bracket to the back of the unit allows us to see the Pump Dispensing Process. 2. Installing Bearings on the Pump Dispensing Arm, prevents it from seizing up. 3. Incorporating a Break away feature on the front of the Pump Dispensing unit has brought an end to the lengthy down time from Damaging Crashes…..

Old E3X Omron Analog Fiber optic sensor New 3rd Generation E3X Advanced Digital sensor

UPGRADING TO THE 21st CENTURY

This new Omron sensor has a 10 times faster response time then its predecessor! It only takes one touch of a button to set this switch up and put in operation, also we have moved the location of the Amplifier from its hiding place embedded inside & underneath the machine to a highly visible easy access location….. This new Amplifier along with New modern fiber optic cables will reduce our reject rate and down-time…….

Short Suction hose Sensor: Before Short Suction hose Sensor: After

EASILY ADJUSTABLE SENSORS

Before After

PUMP GRIPPING CAROUSEL

If you look closely you can see that there is much more open space for an operator or tech to work in, when it comes to adjusting the Pump Gripping Carousel. That’s because we are eliminating all the unneeded parts using improved technology and innovation…..!

Temporary Prototype Permanent Units

F-350 Crimping Station

Our new Permanent Adjustable sensor stands will finally give the operator a legitimate number that correlates to a measurable known distance, by which to set the short stem sensor!

This is the proof of Crimp sensor, it has also

been given a new Easy Adjustable stand….

CRIMPING

The old system for adjusting this sensor was so bad that the operators had resorted to bending it into position! The trouble with doing that, is that it never stays in position for long and results in needless line stoppages…..!

EASY ACCESS & EFFICIENT MAINTENANCE

Access Ports have

been Installed to allow

quick access for

cleaning the vacuum

lines and maintenance.

PUMP/BOTTLE DESPENSING BLOCKIf you look closely you can see the new V-Cone shape which was added to the Pump Carousel which guides curled stems smoothly into the bottle!

Also 3mm has been shaved off the bottom of the Block to prevent it from hitting the crimping star-wheel. This has stopped the unnecessary shaking, so we now run smoothly…

Our Current Star-Wheel New High Performance Model

SELF CLEANING STAR-WHEEL

If you will notice the center of the Star-Wheel on the New unit has a much larger radius than the older model. This along with the large rectangle holes will allow bottles & pumps that always accumulate on top of and in the center of the Star-Wheel to fall through where they are harmless. This will prevent a lot of unnecessary crashes! If you look even closer you will see for each bottle mold there is now a “Hold-down shield”, which will hold each bottle in its proper place while the Crimping action takes place. It will also prevent the bottle from staying lodged in the Crimping device and being carried back around a second time causing crashes and spilling product over the area!

Hold-Down Shields Close-up

ON TARGET EVERYTIME

These Hold-down Shields will secure the bottle in place for more successful Crimping and at the same time prevent Crimped bottles from staying in the Crimp-head and being carried around for a second time, crashing the Crimping machine.

PUMP/BOTTLE DESPENSING BLOCK

Old Block……

New Block: Note the V-Shape Pump stem insertion tunnel “This prevents Pump drop-off due to Curled Pump stems”, and an added 2mm for bottle height adjustment gives us more flexibility to set-up the Pump Carousel

sol.

IMPROVED CRASH SAFETY DEVICEThis Device has been modified to prevent crashes into both the Crimping Head and the Pump Dispenser! It also locks in the tripped position, forcing the operator to inspect before re-start!

Safety Device trigger is set at 1mm in height…..

The old crash sensor only prevented the pump gripper from crashing into the Crimping head, however our new system protects against crashes between both the pump dispenser and the crimp head. This was accomplished by elongating the front section by 2.5 inches and lowering it to a position of 1mm above the pump gripper while it is in its lowest position!

A NEW PUMP GRIPPER ARM

New Design firmly grips the Pump and totally prevents Drop-offs……

Note the lip on the upper Pump gripper! “Drop-offs are responsible for over half our rejects……..”

Through Beam Technology Every Piece Counted

SHORT HOSE SENSOR

Our old sensor used through beam technology, however many curled Pump stems would not be picked up by this application. This new system is full proof, every stem is measured.

MAKING ROOM FOR A BETTER MEASUREMENT

Comparison Comparison

IMPROVED PUMP GRIPPING TIMING

If you notice the timing cam on top is not only shorter, but much less pronounced. That’s because I have shorted the timing side so the gripper grabs the pump as soon as it is passed from the Pump dispenser to the gripper…..! This along with the new Pump Dispenser will bring the dispensing & gripping process to perfection! I also shortened the depth of the cam so the gripper only opens as wide as needed, at present the gripper opens to its full width, 70% more than needed. This puts unnecessary ware & tare on the gripper springs and is the root cause of the springs breaking…….

SUPERB GRIPPING EVERY TIMEEasy to see why pumps dropped off so often, causing crashes and unnecessary downtime for repairs…

Notice how the Pump is setting perfectly in its seat and held firmly, ready to be transferred to the Crimping Head…..

This Simple Innovation completely eliminated Pumps from dropping off at the Pump Gripping Station…..! It was also one of the leading factors in reducing rejects at the Crimping Station.

Adapting the Crimping Head to

Accommodate all Nasonex Components'!

With absolutely no changes to the way the

crimp-head functions, it has been adapted

to allow us to crimp all our Nasonex

components using one style of Crimp-head

NASONEX CRIMPING DEVICE

    While attempting to Crimp the 7.5gm bottle it was found that 70-80% or more were rejected due to a “SKEWED CRIMP” i.e. The Pump severely tilted to either side of the bottle. An attempt was made by the equipment manufacture “IMA” to correct this problem; however their improved design had no positive effect. After studying the Crimping process and our different size components i.e. Pumps and bottles, I was able to adapt our existing equipment to accommodate all our products without changing in any way the functionality of the F-350 Crimping Machine. This all being accomplished for just a fraction of the cost that was spent on the attempt by the manufacture, not to mention the enormous costs had we brought them to Singapore! In conclusion we are now successfully crimping the 17gm, 18gm and the 7.5 gram bottle, all with the same Crimping head. The current reject rate for the 7.5gm unit is around 3-4%, however with the improvements that have been installed since our last 7.5gm production campaign I expect to see that rate drop to 0.5 – 1 percent.     ADAPTING THE CRIMPING PROCESS   The internal shape of the Nipple has been changed from a U-Shape to a counter sink V-Shape, to better guide the Pump into the nipple. “The reason for the counter sink is to accommodate all our Pumps and maintain the narrow guide tunnel so as to center the pump for a straight alignment into the bottle.” NASONEX CRIMPING DEVICE.pptx The Crimp-Head mold has been made 1.5mm deeper, effectively more than doubling its depth. This feature helps in two ways. It greatly increases the surface area for which the vacuum can hold the Pump in its mold during the crimping process. It gives the mold greater stability and holds the Pump firmly in place while inserting it into the bottle, preventing the pump from tilting to either side before Crimping takes place. Due to the fact that we increased the depth of the crimp-head mold, it was necessary to increase the overall length of the crimp-head mold. (In order to maintain the same Pump location in respect to the length of the Crimp-head.) We replaced the spring for the Crimp-Head Nipple to a softer spring. This allows the Pump to be pulled completely into the crimp-head mold, allowing the crimp-head and its mold (“not the nipple”) to push the pump into the bottle. “The nipple was never designed to do this action” We have added 1-2mm shims to the shafts of some of the crimp-heads. So that all the crimp-heads are level and the molds engage the top of the bottle while the bottle sits flat on its platform. At this point we are now crimping the 7.5 gram bottle without the crimping problems we had in the past (the skewed crimp)!

! Seven major components: !* Piston

* Suction nipple

* Capping mold

* Spring

* Spring seat * Crimping fingers

* Closing ring

Only the Suction nipple, Capping mold and the Spring were adapted to achieve our goal

CRIMP-HEAD MAIN COMPONENTS

COMPLETE CRIMPINGThe end result of all

these modifications “A

perfect Crimp, on any

size bottle, using any

Pump” with only one

Crimp-head…….!

F-540 ROTARY FILLING MACHINEThe PM Plan for this Unit has been

revised to include the following!

• Replace wearable Parts on all Valves,

Syringes, Valve guides every 6 months.

• Replace all Bearings Yearly & a

inspection PM conducted Bi-Yearly

• Replace in feed & out feed conveyor

Belts every 4 months.

Very little needed to be modified on this unit as it functions vary well as is! However to increase the performance & reliability it is imperative we enhance the PM Plan and establish a TPM replacement plan to ensure continuous performance with the increased production demands…..! I have set up a Station adjacent to the Line for rebuilding the F-340 filling machine Valves, Syringes and Guides. All the associated parts are now located there for easy access and inventory!

EFFICEANT PM & REPAIRThis Station is equipped with an

abundance of all the wearable

parts associated with the F-340

& F350 filling and Crimping

machines!

All the proper tools, Instructions,

technical references & job aids

are visible and located for easy

access…..!

This Ingenious little Machine is the work of one

of our Engineering Technicians “Siva

Kumar”…….

This Machine will give us the ability to pre-set

the off duty Crimp-heads to a perfect Crimp

setting, on the bench! It will expedite the change

over & start-up time and will allow us to be in a

constant state of readiness with Crimping……

CRIMPING PRE-SET STATION

FINAL SUMMERY• Every PM Plan has been upgraded to enhance the performance & reliability of the

Equipment!

• Error code & Troubleshooting guides, along with a General description & Technical data, Settings & Adjustment Instructions, Format change-over Instructions are positioned at every machine where they are highly visible & ready for use….!

• Detailed Job Aids along with “How too” Photos have been made and are placed at the machine “Highly Visible”……!

• A detailed check-list of “Must Due Maintenance” has been developed, and will be performed in-between batches to keep the line at the highest operating condition at all times.

• A computer is now out on the line, containing a complete set of all Technical manuals for all machines on the line.

• Every Machine has been evaluated for trouble areas and corrected, all difficult adjustments have been made easy & accessible.

• We have tripled the amount of Parts we keep in Stores and down on the line! Plus all Parts on the line have been categorized, Inventoried, and Secured under lock & key.

• We are in progress of replacing all of the PENTA 5XSA DC motors along the entire line conveyor system.

• All conveyor belts and their associated bearings have been replaced.

• The Fiber Optic sensors & Optical sensors on the F-350 and F372 Closing & Capping machines have been upgraded and replaced.

• A special “work station” is now available to rebuild the Crimping heads, Filling valves & associated parts.

• We have developed a “OFF LINE” Crimping station, equipped with special tools for setting & adjusting the Crimp heads to a perfect crimping position 3.85mm.

• We now have two complete sets of Crimping heads that will be rotated in & out of service every 2 weeks or as required. This will allow for expedited maintenance turn around!

• The Ramsey 9000 CHK Weigher for the Primary side has under gone a major upgrade and is now ready to deliver a much higher output!

!• Special tools & equipment have been Invented to perform special tasks & put to use to

enhance troubleshooting and expedite unscheduled maintenance.

•

WHERE WE BELONG