1. “One Team – No Borders”
Krones
Starmatic Labeler
Salad Dressing Line
Downtime Reduction
2. “One Team – No Borders” Introduction
Charter
• Problem Statement - During the first 8 periods of 2011 the Starmatic
Labeler saw 10,285 minutes of downtime and accounted for 30.7% of the
total unplanned equipment downtime for the Liquid Salad Dressing Line.
The reliability of this piece of equipment was responsible for stopping the
filler operation 2,842 times, thus interrupting the production process. At an
average rate of 160 bottles per minute, this downtime accounts for lost
production of 205,702 bottles per period.
• Project Objective – Decrease the Starmatic Labeler unplanned
downtime by at least 50% or 643 minutes per period by March 1, 2012.
This will be accomplished by optimizing the Maintenance Excellence
process to ensure greater reliability and consistency across all three shifts.
This project will deliver an estimated annual cost savings of $58,008 and set
a Maintenance Excellence standard that can be applied across the plant.
4. “One Team – No Borders”
Identifying areas for
Improvement
FMEA
Process Map
Fishbone
5. “One Team – No Borders” Focus Areas
• Preventative Maintenance
• Cleaning and Inspection
• Training / Troubleshooting
• Equipment Repairs
• Changeover
• Material - Labels
6. “One Team – No Borders”
PREVENTATIVE MAINTENANCE
Want to move from Reactive to
Proactive Operations
7. “One Team – No Borders”
Lubrication
Providing a detailed PM
procedure for greasing the
equipment
Daily
Gripper cylinder: 1 drop
per cam roller station
(4) after each caustic
Lubricate pallet turret,
one drop per: bushings
(5 front; 6 back) on
pallets
Lubricate the glue roller
upper/lower bearing
8. “One Team – No Borders”
Lubrication
Weekly
Lubricate remote grease
fittings and check the
reservoir for the bottle
plate
Lubricate the pusher-
plate guide rod on the
label baskets so the
pusher plate travels
smoothly and freely
Oil the rollers on the
cam followers
Lubricate the three
gearwheels underneath
the panel with a light
coating of grease
9. “One Team – No Borders” Inspection
Frequency of Inspection
Monthly vs Quarterly
Procedures
Better detailed equipment checks
Change Over Parts
Inspecting parts
Planned Job Package
Repetitive File 50,000 in EMPAC
Retiming equipment
10. “One Team – No Borders” Inspection
Weekly Visual Inspection
11. “One Team – No Borders” Inventory
Obsolete
Surplus
Location
Standardization
12. “One Team – No Borders”
Cleaning as Inspection
Before After
14. “One Team – No Borders”
Daily Operator Inspection
• Operator Ownership
• Ensures Daily
Inspection Are
Completed
• Identifies
Maintenance Issues
15. “One Team – No Borders”
Operator Training
• Krones Training
• Developing Customized Training Manual
– Knowledge Assessments
• Troubleshooting Guide
16. “One Team – No Borders”
Maintenance Training
Part of the charter was to improve
the efficiency of our mechanics on
identifying breakdowns and the
ability to correct issues quickly with
consistency. This will help eliminate
extended down time events and
create common adjustment points.
17. “One Team – No Borders”
Maintenance Training
Training Program
66 Schedule Krones to Conduct General Equipment training for Operators and
Mechanics
67 Schedule Operators and Mechanics to attend Training (provide necessary
coverage)
68 Document Standardized Work Procedures and SOPs for running equipment
69 Develop operator training plan with certification requirements for future
operators and mechanics
70 Create Troubleshooting Gide
71 Develop daily operator checklist
Developed an action register to determine opportunities for
Maintenance Training
18. “One Team – No Borders” Maintenance Training
• Krones Training:
– Doug Paswatters
– January 3rd thru 6th of 2012
Presented
Cold-Glue Rotary Training for Line
Technicians and Maintenance
19. “One Team – No Borders” Changeovers
• Reviewed the current change over procedures
and updated them to a step by step system to
achieve more consistent results. With this
new format we are looking to have repeatable
change overs that deliver consistency, quality
and reduced time on vertical start up’s.
20. “One Team – No Borders” Changeovers
91 Make a detailed list of all adjustments and settings that can be made to the
labeler
92 Verify set points for each adjustment and each package size
93 Document changeover procedures with SOPs
94 Conduct changeover training with Operators and Mechanics
95 Mark all gages and scales with min/max settings
96 Review current changover procedure
97 Develop Changeover Checklist for Maintenance and Operations
Change Over Action Register
22. “One Team – No Borders” Changeovers
Starmatic Labeler Changeover Sequence
[ ] Back Side of Labeler
Remove: Infeed Guide (adjustment)
Remove: Discharge guide (adjustment)
1 [ ] Remove: Discharge starwheel
2 [ ] Remove: Centerguide
3 [ ] Remove: Infeed starwheel
4 [ ] Remove: Feedscrew
5 [ ] Install: Feedscrew, and adjust to package"
Remove: Bottle gate (adjustment)
6 [ ] Install: Infeed starwheel
Install: Infeed guide - (adjust)
7 [ ] Install: Centerguide
8 [ ] Install: Discharge starwheel
9 [ ] Install: "Discharge guide, as required"
Front Aggregate
10 [ ] Remove: Front Label basket *The Operator should have this done before the Mechanics are finished with the Back Side of the Labeler. (Do not lift using pusher-plate rails)
11 [ ] Remove: Front Label pallets *The Operator should have this done before the Mechanics are finished with the Back Side of the Labeler.
12 [ ] Install: Label basket (do not lift using pusher-plate rails.)
13 [ ] Remove: Front Gripper cylinder
14 [ ] Install: Front Gripper cylinder
15 [ ] Install: Front Label pallets
Back Aggregate
16 [ ] Remove: Back Label basket *The Operator should have this done before the Mechanics are finished with the Back Side of the Labeler. (Do not lift using pusher-plate rails)
17 [ ] Remove: Back Label pallets *The Operator should have this done before the Mechanics are finished with the Back Side of the Labeler.
24. “One Team – No Borders”
Equipment Repairs
Lack of proper cleaning and PM’s lead to a labeler that was unreliable,
unpredictable and in need of immediate attention.
25. “One Team – No Borders”
Equipment Repairs
• Team identified repair opportunities and
formed action register.
Train oilers and supervisors on new lubrication schedule
Run water line
Cam Rollers are Worn and need to be replaced
Replace all sight glasses on labeler
Replace all oil reservoirs on labler
Replace all gages on labeler
Replace rubber seals on all of the doors
Clean / Replace all door frames
Infeed star - center hub is cracked, make sure we have a spare
Small lexan panel by the back label did not get replaced during cleaning -
replace small lexan panel
Check drive belt tension so that it can be added to the PM
Update PMs with information from cleaning day, past history and FMEA
Install quick release handles for removing brushes for cleaning
Research and develop plan for replacing/rebuilding main gear box
Insvestigate scheduing PMs on hours vs. days
26. “One Team – No Borders”
Equipment Repairs
• As part of the action register and PM review we replaced over
60 different worn parts
27. “One Team – No Borders”
Equipment Repairs
• Some parts that were replaced
Out with the old In with the new
28. “One Team – No Borders” Future Work
We will change the
culture to create a cleaner,
well maintained and
efficient running Labeler
29. “One Team – No Borders” Future Work
Improved Lubrication Program
30. “One Team – No Borders” Future Work
New established cleaning procedures
31. “One Team – No Borders” Future Work
Improved PM Procedures
32. “One Team – No Borders” Future Work
Through Training and Team Work
33. “One Team – No Borders” Label Check Sheet
Kroger State Ave - Labeler Check Sheet Operator:____________________________
Date:_______________________________
Time Product Name Front Label Back Label Neck Band Cap Type
Align Adhes Resource# Align Adhes Resource# Align Adhes Resource# Blue Red
1 Pre-Op
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
The first check is now considered the pre-op check. Once the labels are applied and in specifications and code dater blue and red have been set and the correct caps are in use
perform the first quality check, While performing this check the line must be down when the containers meet the specifications then continue running production.
It is important when checking the code dates to make sure both code daters are set correctly and are printing in the correct location on the container.
Every half hour and each changeover, check 3 containers for label alignment and proper adhesion of each label. If each label is
acceptable, write "YES" in the blank provided. If not, write "NO" and note what was done to correct it in the comments section. Check the cap type
against the pack specs. (Color/lined vs. unlined, etc) IF THE RESORCE NUMBER SPEC AND THE RESOURCE NUMBER USED DO NOT MATCH
OR LABELS CANNOT BE APPLIED PROPERLY, SHUT THE LINE DOWN AND CONTACT A SUPERVISOR. Alignment should be no more than
1/4 inch skewed.
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
Revised 2/09/12 JB
Date Coder
• Operator
Accountability
• Operator
Awareness
• Eliminates
Failure of
Process
Improvement
34. “One Team – No Borders” Labels
Spring Dot was here on January
24 and brought in their operators
and upper management as well
as one of their owners for this
meeting.
We used samples during the
meeting as examples of improper
cuts.
Spring Dot response:
We can just make the switch as
soon as you can purchase the
correct paper and obsolete the
old inventory.
36. “One Team – No Borders” Control Plan
Sustained Improvement Requires….
• Involvement and Attention from Everyone!
– Operators, Mechanics, Production and Maintenance Supervisors,
Superintendent, Maintenance Manager, Maintenance Engineer, QA, Kaizen
Team, HR….
** Control Plan will be reviewed
with all necessary parties for
approval and signatures
37. “One Team – No Borders” Results
Minutes of Starmatic Labeler Downtime by Period
39. “One Team – No Borders” Downtime Trend
Reduced Variation
40. “One Team – No Borders” Results
Baseline
#1 Downtime Event = Labeler
30.7% of Downtime caused by Labeler
After Improvements
#1 Downtime Event = Changeover
24.2% of Downtime caused by Changeover
17.8% of Downtime caused by Labeler
41. “One Team – No Borders”
Improvement and Savings
Avg. DT Min
/Shift
Baseline
(1/30/11 – 12/6/11)
After
Improvements
(12/7/11 - Present)
50% Reduction
Goal
%
Improvement
1st
10.4 10.8 10.0 ------
2nd
29.5 15.8 10.0 46%
3rd 20.2 15.2 10.0 25%
Total 60.1 41.8 30.0 30%
** In the 7 shifts since the maintenance/rebuild on 2/18-2/19 we have averaged
3.98 minutes of downtime per shift! That’s an 80% improvement from the baseline
average.
42. “One Team – No Borders” Projected Savings
$0.00
$20,000.00
$40,000.00
$60,000.00
$80,000.00
$100,000.00
12 13 1 2 3 4 5 6 7 8 9 10 11
Project Savings - Calculated from Unplanned Downtime % Improvement
** Savings calculated from average period downtime reduction only
30% Projected Improvement 50% Projected Improvement 75% Projected Improvement 90% Projected Improvement
43. “One Team – No Borders”
What’s Next?
30% Improvement = Current State
50% Improvement = Expectation after 2/18-2/19 Weekend Repairs
75% Improvement = Projected improvement after completion of the following:
• Customized Operator Training Manual, Troubleshooting and Training
• Improved Springdot Label Quality
• Neck Band Labels with Horizontal Grain (3/17)
• Downtime Code Standardization
90 % Improvement = Recommendations for future Teams/Kaizen Events
• Rapid Changeover Event
• Customized Maintenance Training Manual and Training Program
• Cleaning Cabinet
** Control Plan Must Be Followed to Sustain Improvements
