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How to Increase Efficiencies byRemoving Changeover
Agenda✓   1   Mistakes to avoid when minimizing changeover    2   Conveyor systems and equipment options    3   Product ha...
Agenda    1   Mistakes to avoid when minimizing changeover✓   2   Conveyor systems and equipment options    3   Product ha...
Agenda    1   Mistakes to avoid when minimizing changeover    2   Conveyor systems and equipment options✓   3   Product ha...
Agenda    1   Mistakes to avoid when minimizing changeover    2   Conveyor systems and equipment options    3   Product ha...
Agenda    1   Mistakes to avoid when minimizing changeover    2   Conveyor systems and equipment options    3   Product ha...
Agenda    1   Mistakes to avoid when minimizing changeover    2   Conveyor systems and equipment options    3   Product ha...
Agenda    1   Mistakes to avoid when minimizing changeover    2   Conveyor systems and equipment options    3   Product ha...
Avoid                  Mistakes to AvoidAccumulationThrough Turns                  Accumulation Through Turns   Extreme  D...
Mistakes to Avoid   Excessive    Product       Extreme Diversity of Products   Crowding   Extreme  Diversity Of   Products...
Mistakes to Avoid Excessive  Product Crowding               Combining High Speed With Manipulation ExtremeDiversity Of Pro...
Mistakes to Avoid   Excessive    Product       Failure to Consider Operating Costs   Crowding   Extreme  Diversity Of   Pr...
Conveying Equipment                          Best Uses                             Carton Handling                       ...
Conveying EquipmentDrum Spiral Conveyors   Drum Spiral
Conveying Equipment                        Best Uses                           Product Flexibility                       ...
Conveying EquipmentSerpentine Accumulators   Serpentine Accumulators
Conveying Equipment                          Best Uses                             Product that can’t                    ...
Conveying EquipmentReflow Accumulating Table
Conveying Equipment                            Best Uses                               Round product                     ...
Conveying EquipmentBi-Directional Table   Bi-Directional Table
Conveying Equipment                       Best Uses                          Round Containers                          V...
Conveying EquipmentNercon Knowledge Center   Media Center
Conveying Equipment                                    Best Uses                                       Product versatilit...
Conveying EquipmentARB Technology
Conveying Equipment                      Best Uses                         Handles various                          types...
BEFORE
AFTER
Conveying Equipment                       Live Roller                       Metering/Merging                       Conveyo...
Conveying Equipment                                Best Uses                                 •   Low profile products     ...
BEFORE
AFTER
POLL QUESTION:What do you consider a minimum acceptablepayback for capital purchase projects?   1. 6 months or less   2. 6...
BEFORE: A system example
BEFORE: A system exampleBUMP TURN                           Bump Turns
BEFORE: A system exampleCLAMP
BEFORE: A system exampleSTAR WHEEL UPENDER                           Star Wheel Upender
After: A system example
After: A system exampleWIDE EDGE LEADING PRODUCT FLOW
After: A system exampleDUAL CHAIN CASE TURNERS
After: A system exampleSTAR WHEEL – on Sliding Carraige
After: A system example                              Manual Pack                                Station                   ...
DevicesDual Lane Rotator   Star-wheel Upender
Product Handling CharacteristicsRound Containers   Oval Containers      Cartons           Cases              Pouches
Round Containers                   • Single dimension                   • No orientation                   • Easier to gro...
Round Containers
Oval Containers                  • Orientation                  • Tapered containers                  • Traveling on lids/...
Oval Containers
Cartons          • Challenges traveling hard way          • Orientation issues          • Needs of assembly line equipment...
Easy Way Vs. the Hard WayEasy Way             Hard Way
Cases        • Typically sizes on case erectors          are close in dimensional sizes        • Elevating equipment shoul...
Flexible Packages                    • Watch out for flaps & seals                    • Accumulation causes product       ...
ARB System ExampleBEFORE                       AFTER                                     UPTIME / LABOR                   ...
Live Roller Merge ExampleBEFORE                     AFTER                                    UPTIME                       ...
ROI                          FUTURE      UPTIME                           SALES       How to Increase Line Efficiency by  ...
THANK YOU!For more information, visit      our website    www.nercon.com    Check out our blog!    Change-over White Paper
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How to Increase Conveyor Line Efficiencies by Removing Change-over

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How to Increase Conveyor Line Efficiencies by Removing Change-over

  1. 1. How to Increase Efficiencies byRemoving Changeover
  2. 2. Agenda✓ 1 Mistakes to avoid when minimizing changeover 2 Conveyor systems and equipment options 3 Product handling considerations 4 Line layout recommendations and examples 5 Controls and logic requirements 6 Cost comparisons and payback 7 Live Q & A breaks
  3. 3. Agenda 1 Mistakes to avoid when minimizing changeover✓ 2 Conveyor systems and equipment options 3 Product handling considerations 4 Line layout recommendations and examples 5 Controls and logic requirements 6 Cost comparisons and payback 7 Live Q & A breaks
  4. 4. Agenda 1 Mistakes to avoid when minimizing changeover 2 Conveyor systems and equipment options✓ 3 Product handling considerations 4 Line layout recommendations and examples 5 Controls and logic requirements 6 Cost comparisons and payback 7 Live Q & A breaks
  5. 5. Agenda 1 Mistakes to avoid when minimizing changeover 2 Conveyor systems and equipment options 3 Product handling considerations✓ 4 Line layout recommendations and examples 5 Controls and logic requirements 6 Cost comparisons and payback 7 Live Q & A breaks
  6. 6. Agenda 1 Mistakes to avoid when minimizing changeover 2 Conveyor systems and equipment options 3 Product handling considerations 4 Line layout recommendations and examples✓ 5 Controls and logic requirements 6 Cost comparisons and payback 7 Live Q & A breaks
  7. 7. Agenda 1 Mistakes to avoid when minimizing changeover 2 Conveyor systems and equipment options 3 Product handling considerations 4 Line layout recommendations and examples 5 Controls and logic requirements✓ 6 Cost comparisons and payback 7 Live Q & A breaks
  8. 8. Agenda 1 Mistakes to avoid when minimizing changeover 2 Conveyor systems and equipment options 3 Product handling considerations 4 Line layout recommendations and examples 5 Controls and logic requirements 6 Cost comparisons and payback✓ 7 Live Q & A breaks
  9. 9. Avoid Mistakes to AvoidAccumulationThrough Turns Accumulation Through Turns Extreme Diversity Of ProductsCombining Speed With Product Manipulation Failure to Consider Operating Costs
  10. 10. Mistakes to Avoid Excessive Product Extreme Diversity of Products Crowding Extreme Diversity Of ProductsCombining Speed With Product Manipulation Failure to Consider Operating Costs
  11. 11. Mistakes to Avoid Excessive Product Crowding Combining High Speed With Manipulation ExtremeDiversity Of Products CombiningSpeed With ProductManipulation Failure to Consider Operating Costs
  12. 12. Mistakes to Avoid Excessive Product Failure to Consider Operating Costs Crowding Extreme Diversity Of ProductsCombining Speed With Product Manipulation Failure to Consider Operating Costs
  13. 13. Conveying Equipment Best Uses  Carton Handling  Case Handling  Bundle Handling  Speeds 30 CPM  Product weights less than 40 lbs.Vertical Conveyor Lifts Vertical Conveyors
  14. 14. Conveying EquipmentDrum Spiral Conveyors Drum Spiral
  15. 15. Conveying Equipment Best Uses  Product Flexibility  Product Diversity  High Capacity  Mass Flow  Higher Rate Applications  Multiple product orientation  Product stabilityDrum Spiral Conveyors
  16. 16. Conveying EquipmentSerpentine Accumulators Serpentine Accumulators
  17. 17. Conveying Equipment Best Uses  Product that can’t handle back pressure  First-In, First-Out  Accumulates during short down-timesSerpentine Accumulators
  18. 18. Conveying EquipmentReflow Accumulating Table
  19. 19. Conveying Equipment Best Uses  Round product shapes  Small footprint  Low backpressure accumulation  Minimal controls requiredReflow Accumulating Table Accumulation Tables
  20. 20. Conveying EquipmentBi-Directional Table Bi-Directional Table
  21. 21. Conveying Equipment Best Uses  Round Containers  Various Sizes without Rail Changes  Off line storageBi-Directional Table
  22. 22. Conveying EquipmentNercon Knowledge Center Media Center
  23. 23. Conveying Equipment Best Uses  Product versatility – tapered containers, non- round shapes  Single Filing without Changeover  Mass Flow  Product AlignmentSingle Filer / Combining Conveyor Pressureless Combiner
  24. 24. Conveying EquipmentARB Technology
  25. 25. Conveying Equipment Best Uses  Handles various types of products and shapes  High Capacity / Rate  Weight variety  Product variationARB Technology
  26. 26. BEFORE
  27. 27. AFTER
  28. 28. Conveying Equipment Live Roller Metering/Merging ConveyorLive Roller Metering /Merging Conveyor
  29. 29. Conveying Equipment Best Uses • Low profile products • Hard to handle packages • No backpressure • Multi-lane mergingLive Roller Metering/Merging Conveyor
  30. 30. BEFORE
  31. 31. AFTER
  32. 32. POLL QUESTION:What do you consider a minimum acceptablepayback for capital purchase projects? 1. 6 months or less 2. 6 to 12 months 3. 1 to 2 years 4. Over 2 years
  33. 33. BEFORE: A system example
  34. 34. BEFORE: A system exampleBUMP TURN Bump Turns
  35. 35. BEFORE: A system exampleCLAMP
  36. 36. BEFORE: A system exampleSTAR WHEEL UPENDER Star Wheel Upender
  37. 37. After: A system example
  38. 38. After: A system exampleWIDE EDGE LEADING PRODUCT FLOW
  39. 39. After: A system exampleDUAL CHAIN CASE TURNERS
  40. 40. After: A system exampleSTAR WHEEL – on Sliding Carraige
  41. 41. After: A system example Manual Pack Station Redesigned for Robotic Pick-up.END – OF – LINE AUTOMATION
  42. 42. DevicesDual Lane Rotator Star-wheel Upender
  43. 43. Product Handling CharacteristicsRound Containers Oval Containers Cartons Cases Pouches
  44. 44. Round Containers • Single dimension • No orientation • Easier to group similar sizes in guiderails
  45. 45. Round Containers
  46. 46. Oval Containers • Orientation • Tapered containers • Traveling on lids/caps • Puck transportation to eliminate changeover (same pucks)
  47. 47. Oval Containers
  48. 48. Cartons • Challenges traveling hard way • Orientation issues • Needs of assembly line equipment • Top load/End load/Side load • Length vs Width
  49. 49. Easy Way Vs. the Hard WayEasy Way Hard Way
  50. 50. Cases • Typically sizes on case erectors are close in dimensional sizes • Elevating equipment should handle multiple sizes without changeover • Justification can help eliminate changeover
  51. 51. Flexible Packages • Watch out for flaps & seals • Accumulation causes product shingling and or damage • Can cause jams and issues with interface equipment • Similar pouches can be looked at for eliminating change over
  52. 52. ARB System ExampleBEFORE AFTER UPTIME / LABOR $39,500 / Year 1.5 Years FUTURE SALES $36,000 / Year 1.7 Years Best Case .80 Worst Case 1.46INPUT DATA8 Hrs / Day, 250 Days / YearEQUIPMENT COST: $60,000LABOR SAVED: 15 Min / DayLABOR RATE: $30 / HrUNIT PROFIT: $0.25 / UnitTHROUGHPUT: 40 / Min.FUTURE SALES: 3% / Year
  53. 53. Live Roller Merge ExampleBEFORE AFTER UPTIME $34,312.00 1.05 Years FUTURE SALES $14,670.00 2.45 Years Best Case 0.73INPUT DATA Worst Case 1.458 Hrs / Day, 250 Days / YearEQUIPMENT COST: $36,000LABOR SAVED: 30 Min/dayLABOR RATE: $30/ Hr.UNIT PROFIT: $0.25/ UnitTHROUGHPUT: 16 / Min.FUTURE SALES: 3% / Year
  54. 54. ROI FUTURE UPTIME SALES How to Increase Line Efficiency by Removing Changeover
  55. 55. THANK YOU!For more information, visit our website www.nercon.com Check out our blog! Change-over White Paper

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