At AUSPACK 2017 RK Rose+Krieger will demonstrate how flexible format adjustment solutions can increase efficiency in the changeover process.
As demand for variety in packaging format and materials continues to increase, so too must production line flexibility – streamlining format adjustment can play a significant role.
According to Sascha Humphreys of RK Rose+ Krieger's Australian partner Phoenix Mecano, there are three main challenges typically faced by manufacturers and packaging converters.
Firstly, the growing requirement for smaller production runs – either as requested by customers, or as an initiative to minimise stock holdings.
Secondly, as an increased number and variation of goods are produced, the efficiency of producing in large batches/long runs is reduced; attention needs to be directed at keeping production rates up and costs down, even when more variants and shorter runs are required.
And thirdly, customers are demanding shorter lead times. “Running your machines on the same product for longer is the best way to keep unit costs down, however, for each long production run, the total lead time you can offer your customer is affected,” Humphreys says.
“For example, if you run one product for one full week, you can only offer four to five customers/products with a one-month lead time," he says. "But, if a streamlined changeover is possible, then you could run one different product per day, and so offer the same number of customers/products, but instead with a one-week lead time on smaller batches.”
Humphreys say that output can be increased in one of two ways:
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increasing machine speeds, which can increase component wear and decrease machine life, and may also introduce safety issues; and
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minimising changeover times, by changing a machine or production line to suit a different product/packaging size. This can be simple for a localised adjustment, but is more often quite difficult; for example adjusting all the guiderails on a long conveyor, or even for making adjustments to equipment which is overhead or difficult to reach.
Format adjustment solutions
Existing methods that enable more efficient machine changes include the use of easy-to-adjust clamps, adjustable screws and handwheels .
More complex and expensive methods include running adjustments with an electric motor, or integrating the position and control of such motors into the overall machine control.
If special parts, such as dies and tools – or even more simple components like specific fingers or plates (that suit only a small quantity of products/product sizes) – need to be changed over, Humphreys' says one of the following options could be considered:
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Group like product runs together; one special part could be used for a group of different products, rather than needing to change each time.
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Introduce ‘tool-less’ methods of swapping over special parts – considerable savings can be made if staff do not need to find/bring tools with them; instead the parts to be changed have built-in or standard fixing handles to enable change without tools.
"Implementing a new system provides an obvious opportunity for improved productivity and performance, however there’s also a huge potential for increased efficiency in existing systems," Humphreys says.
"Production systems where components still require time-consuming manual adjustment work, such as adjustment wheels, guides with clamping devices or cylinders with limit stops, can be retrofitted," he adds.
Humphreys notes that as well as the time factor, the increased quality and reduction of waste when the system is re-started following a format changeover cannot be underestimated.
"The more manual format adjustments are installed in a system and the more complex the system is as a whole, the quicker the investment in an automated positioning solution will pay off."
The RK Rose+Krieger linear actuator modular system makes automation quick and easy to achieve. Find out more at AUSPACK by visiting Stand 301
