1. Transforming the Nasonex
Packaging line into a High-
Speed, High-Output Operation
PACKAGING OPPERATIONS,
SINGAPORE, IPT WEST
TABLET FACILITY

2. • 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

3. 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

4. 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 .

5. OUR PREVIOUS CARTONER
The IMA Flexa Intermittent Cartoner

6. Uhlmann C 2205 Cartonator
Our New Cartoner

7. 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

8. 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.

9. IMPROVINGTHE DISPENSING UNIT

10. Made More Reliable & Less Costly to Operate!
O.Z.A.F
UNSCRAMBLING UNITS

11. O.Z.A.F
AC-1500
UNSCRAMBLER
FEEDING SYSTEM

12. Before 100kg After 55kg
Lighten the load

13. One of Eight selection disks One of two center pieces
Maintaining Balance

14. Panasonic motor & gear box The OZAF AC-1500 Feeder
Too much of a job for a little drive unit

15. 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………..

16. 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!

17. 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.

18. 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

19. RAMSEY 9000 OUTFEED SYSTEM
Keeping it Simple

20. EASY OUT
KEEPING IT SIMPLE
My design is simple,
no wearable moving
Parts, no
Maintenance cost!
Cost: $800 SG

21. Our Old System The New System
HIT OR MISS

22. From Start To Finish
ONTARGET

23. Speedy Replacement Simplicity
REPLACING PARTS MADE FAST & SIMPLE

24. 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…..!

25. Fast, Stable, Reliable!

26. 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!

27. THE PUMP DISPENSING HEAD
Adjusting 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.

28. The original Pump Dispenser Our Improved Pump Dispenser
TO SEE OR NOTTO SEE….?

29. 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.

30. Old E3X Omron Analog Fiber optic sensor New 3rd Generation E3X Advanced Digital sensor
UPGRADINGTOTHE 21st CENTURY

31. Short Suction hose Sensor: Before Short Suction hose Sensor: After
EASILY ADJUSTABLE SENSORS

32. Before After
PUMP GRIPPING CAROUSEL

33. Temporary Prototype Permanent Units
F-350 Crimping Station

34. This is the proof of Crimp sensor, it has
also been given a new Easy Adjustable
stand….
CRIMPING

35. EASY ACCESS & EFFICIENT
MAINTENANCE
Access Ports have
been Installed to
allow quick access
for cleaning the
vacuum lines and
maintenance.

36. 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…

37. Our Current Star-Wheel New High Performance
Model
SELF CLEANING STAR-WHEEL

38. Hold-Down Shields Close-up
ONTARGET EVERYTIME

39. 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.

40. 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…..

41. 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……..”

42. Through Beam Technology Every Piece Counted
SHORT HOSE SENSOR

43. MAKING ROOM FOR A BETTER
MEASUREMENT

44. Comparison Comparison
IMPROVED PUMP GRIPPINGTIMING

45. 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…..

46. 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

47. 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

48. COMPLETE CRIMPING
The end result of all
these modifications
“A perfect Crimp, on
any size bottle, using
any Pump” with only
one Crimp-head…….!

49. 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.

50. EFFICEANT PM & REPAIR
This 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…..!

51. 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

52. 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 “HighlyVisible”……!
• 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.

53. • 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.
•

54. WHEREWE BELONG