packaging operations, singapore, ipt west tablet facility
TRANSCRIPT
Transforming the Nasonex Packaging line into a High-Speed, High-Output Operation
PACKAGING OPPERATIONS, SINGAPORE, IPT WEST TABLET FACILITY
• 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
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
MS-300 STRATCH-BANDING MACHINE
We ‘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 .
OUR PREVIOUS CARTONERThe IMA Flexa Intermittent Cartoner
Uhlmann C 2205 CartonatorOur New Cartoner
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
F-572 PLUGGING &CAPING MACHINE
Their 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.
IMPROVING THE DISPENSING UNIT
Made More Reliable & Less Costly to Operate!
O.Z.A.F UNSCRAMBLING UNITS
O.Z.A.F
AC-1500
UNSCRAMBLER FEEDING SYSTEM
Before 100kg After 55kg
Lighten the load
One of Eight selection disks One of two center pieces
Maintaining Balance
Panasonic motor & gear box The OZAF AC-1500 Feeder
Too much of a job for a little drive unit
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!
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.
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
RAMSEY 9000 OUTFEED SYSTEM
Keeping it Simple
EASY OUTKEEPING IT SIMPLE
My design is
simple, no
wearable moving
Parts, no
Maintenance cost!
Cost: $800 SG
Our Old System The New System
HIT OR MISS
From Start To Finish
ON TARGET
Speedy Replacement Simplicity
REPLACING PARTS MADE FAST & SIMPLE
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…..!
EFFICENT CRIMPING
Fast, Stable, Reliable!
F-350 ROTARY CLOSING MACHINE
Numerous 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 original Pump Dispenser Our Improved Pump Dispenser
TO SEE OR NOT TO SEE….?
IMPROVED PUMP DISPENSING UNIT
1. 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.
Old E3X Omron Analog Fiber optic sensor New 3rd Generation E3X Advanced Digital sensor
UPGRADING TO THE 21st CENTURY
Short Suction hose Sensor: Before
Short Suction hose Sensor: After
EASILY ADJUSTABLE SENSORS
Before After
PUMP GRIPPING CAROUSEL
Temporary Prototype Permanent Units
F-350 Crimping Station
This is the proof of Crimp sensor,
it has also been given a new
Easy Adjustable stand….
CRIMPING
EASY ACCESS & EFFICIENT MAINTENANCE
Access Ports have
been Installed to
allow quick access
for cleaning the
vacuum lines and
maintenance.
PUMP/BOTTLE DESPENSING BLOCK
If 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
Hold-Down Shields Close-up
ON TARGET EVERYTIME
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 DEVICE
This 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…..
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
MAKING ROOM FOR A BETTER MEASUREMENT
Comparison Comparison
IMPROVED PUMP GRIPPING TIMING
SUPERB GRIPPING EVERY TIME
Easy 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…..
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
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 CRIMPING
The 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 MACHINE
The 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.
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