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Changeover Webinar

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Best practices for selecting different levels of Changeover technology. Learn key criteria in Changeover controls, layout recommendations, and accessibility considerations.

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Changeover Webinar

  1. 1. How to Reduce Changeover Time with Conveyor TechnologyThe Conveyor’s Role inChangeover Processes
  2. 2. Agenda1. Manual – Single Adjustment Changeover
  3. 3. Agenda1. Manual – Single Adjustment Changeover2. Manual – Multi-point Adjustment Changeover
  4. 4. Agenda1. Manual – Single Adjustment Changeover2. Manual – Multi-point Adjustment Changeover3. Automatic Rail Systems
  5. 5. Agenda1. Manual – Single Adjustment Changeover2. Manual – Multi-point Adjustment Changeover3. Automatic Rail Systems4. Accessibility Considerations
  6. 6. Agenda1. Manual – Single Adjustment Changeover2. Manual – Multi-point Adjustment Changeover3. Automatic Rail Systems4. Accessibility Considerations5. Best Practices for selecting different levels of technology
  7. 7. Agenda1. Manual – Single Adjustment Changeover2. Manual – Multi-point Adjustment Changeover3. Automatic Rail Systems4. Accessibility Considerations5. Best Practices for selecting different levels of technology6. Layout Recommendations
  8. 8. Agenda1. Manual – Single Adjustment Changeover2. Manual – Multi-point Adjustment Changeover3. Automatic Rail Systems4. Accessibility Considerations5. Best Practices for selecting different levels of technology6. Layout Recommendations7. Decision Matrix
  9. 9. CriteriaPURCHASE COST Initial CostBRACKET PRICING □$ □ $$Less than $5,000 □ $$$ Man Hours □+Between $5,000 - $15,000 □++ □+++ AdaptableOver $15,000 □ Yes □ No Controls □ None □ Simple □ Complex
  10. 10. Criteria CHANGEOVER Initial Cost MAN HOURS □$ □ $$ □ $$$ + Few seconds Man Hours □+ □++++ Moderate – less than ½ hour □+++ Adaptable Many – over ½ hour □ Yes+++ □ No Controls □ None Per 100 / ft. of conveyor □ Simple □ Complex
  11. 11. CriteriaIs the solution adaptable? Initial Cost □$ □ $$ □ $$$ Man Hours □+ □ ++ □ +++ Adaptable □ Yes □ No Controls □ None □ Simple □ Complex
  12. 12. CriteriaCONTROLS Initial Cost □$ □ $$ □ $$$ Man Hours □+ □ ++ □ +++ Adaptable □ Yes □ No Controls □ None □ Simple □ Complex
  13. 13. Manual SolutionsTool – less brackets Initial Cost P □$ □ $$ □ $$$ Man Hours □+ □ ++ P □ +++ Adaptable □ Yes P □ No Controls □ None P □ SimpleQuick Set with Hand Knob Ratchet Handle □ Complex
  14. 14. Manual SolutionsTool – less brackets Initial Cost P □$ □ $$ □ $$$ Man Hours □ + □ ++ P □ +++ Adaptable □ Yes P □ No Controls □ None P □ Simple Ratchet Handle with Ruler Guide □ Complex
  15. 15. Manual SolutionsGuide Rail Systems – Adjustable Zones Initial Cost P □$ □ $$ □ $$$ Man Hours □+ P □ ++ □ +++ Adaptable □ Yes □ No P Controls □ None P □ SimpleMin - Max Pin-in-place system □ Complex
  16. 16. Manual SolutionsGuide Rail Systems – Adjustable Zones Initial Cost □$ P □ $$ □ $$$ Man Hours □ + P □ ++ □ +++ Adaptable □ Yes □ No P ControlsDrop – In Rail Systems □ None P □ Simple □ Complex
  17. 17. Manual SolutionsGuide Rail System – Adjustable Zones Initial Cost □$ P □ $$ □ $$$ Man Hours □+ P □ ++ □ +++ Adaptable □ Yes □ No P Controls □ None P □ Simple □ ComplexFlip – In Rail Systems
  18. 18. Manual SolutionsGuide Rail Systems – Adjustable Zones Initial Cost □$ P □ $$ □ $$$ Man Hours P □+ □ ++ □ +++ Adaptable P □ Yes □ No Controls □ None P □ Simple □ Complex Hand Wheel VideoHand Wheel with Digital Counter
  19. 19. Manual SolutionsGuide Rail Systems – Adjustable Zones Initial Cost □$ P □ $$ □ $$$ Man Hours P □+ □ ++ □ +++ Adaptable P □ Yes □ No Controls □ None P □ Simple □ Complex
  20. 20. Manual SolutionsGuide Rail System – Adjustable Zones Initial Cost □$ P □ $$ □ $$$ Man Hours P □+ □++ □+++ Adaptable P □ Yes □ No Controls P □ None □ Simple □ Complex
  21. 21. Layout Example - Manual
  22. 22. Layout Example - Manual MASS FLOW NO CHANGEOVER
  23. 23. Layout Example - Manual Hand Wheel with Digital Counter
  24. 24. Layout Example - Manual RATCHET HANDLES
  25. 25. Layout Example - Manual RATCHET HANDLES
  26. 26. Questions? Take our poll. What is your primary reason for researching changeover solutions? 1. Increase in just-in-time production requirements 2. Product line expansion 3. To increase line-efficiencies 4. Lean manufacturing corporate strategy
  27. 27. AccessibilityAccess Lift Gate
  28. 28. AccessibilityPlatforms
  29. 29. POLL RESULTS What is Your Primary Reason for Researching Changeover Technology? Product line expansion 2 Increase in just-in-time production 6 requirementsLean manufacturing corporate strategy 12 To increase line-efficiencies 18 0 2 4 6 8 10 12 14 16 18 20
  30. 30. Automatic SolutionsSingle Sided Initial Cost □$ □ $$ P □ $$$ Man Hours P □+ □ ++ □ +++ Adaptable □ Yes □ No P Controls □ None P □ Simple □ ComplexPneumatic Drop-In Rail System
  31. 31. Automatic SolutionsSingle Sided Initial Cost □$ □ $$ P □ $$$ Man Hours P □+ □ ++ □ +++ Adaptable □ Yes □ No P Controls □ None P □ Simple □ ComplexPneumatic Push-In Rail System
  32. 32. Automatic SolutionsDual Sided Initial Cost □$ □ $$ P □ $$$ Man Hours P □+ □ ++ □ +++ Adaptable □ Yes P □ No Controls □ None P □ Simple □ Complex
  33. 33. Automatic SolutionsComparing Pneumatic and Electric Cylinders Pneumatic Electric
  34. 34. Changeover Equipment Initial CostGripper □$Elevator P □ $$ □ $$$ Man Hours P □+ □ ++ □ +++ Adaptable P □ Yes □ No Controls P □ None □ Simple □ ComplexHand Wheel Gripper Elevator Video
  35. 35. Changeover Equipment Initial CostCase Elevator □$ P□ $$ □ $$$ Man Hours P□+ □ ++ □ +++ Adaptable P □ Yes □ No Controls P □ None □ Simple □ ComplexHand Wheel Case Elevator Video
  36. 36. Product Considerations
  37. 37. Product Considerations
  38. 38. Product Considerations
  39. 39. Automatic Solutions
  40. 40. Automatic Solutions POWERED DIAL INDICATOR
  41. 41. Automatic Solutions POWERED DIAL INDICATOR
  42. 42. Automatic Solutions POWERED DIAL INDICATOR
  43. 43. Automatic Solutions ELECTRIC ACTUATED AUTOMATIC RAIL SYSTEM
  44. 44. Cost versus Man Hours 100 Feet of Straight Conveyor $30 / hour Labor Rate 250 Changeovers Per Year
  45. 45. Cost versus Man Hours 100 Feet of Straight Conveyor $30 / hour Labor Rate 250 Changeovers Per Year Set Points
  46. 46. Cost versus Man Hours BASELINE 108 Adjustment Points $7,500 in labor 60 Min. 250 hrs. lost/year
  47. 47. Cost versus Man Hours Level 1: RATCHET HANDLE 108 Adjustment Points $5,625 in labor 45 Min. $1,000 forthe ratchet 188 Hrs. handles Lost/Yr.
  48. 48. Cost versus Man Hours Level 2: RATCHET HANDLE With Pre-Measured Points 108 Adjustment Points $3,750 in labor 30 Min.$2,000 for the ratchet handles and pre-measured set points 125 Hrs. Lost/Yr.
  49. 49. Cost versus Man Hours Level 3: RATCHET HANDLE one side 54 Adjustment Points $1,875 in labor 15 Min.$1,500 for the ratchet handles and pre-measured set points 62 Hrs. Lost/Yr.
  50. 50. Cost versus Man Hours Level 4: HAND WHEEL DIAL INDICATOR One Side 3 Adjustment Points $625 in labor 5 Min.$22,500 for rail 20 Hrs. system Lost/Yr.
  51. 51. Cost versus Man Hours Level 5: AUTOMATIC ADJUSTABLE With Operator Push Button Station 1 Adjustment Point $125 in labor 1 Min.$27,500 for rail 4 hrs. system Lost/Yr.
  52. 52. Changeover White Paper Download White Paper
  53. 53. Cost versus Man Hours 10 YEAR Labor Cost Versus Purchase Cost 80000 BASE 70000 60000 MANUAL 50000 SETCOST $ 40000 POINTS COST AUTO- LABOR 30000 HAND MATIC WHEEL 20000 ONE SIDE 10000 0 1 2 3 4 5 6 CHANGEOVER SOLUTIONS Manual Automatic
  54. 54. Questions?
  55. 55. Thank you for attending! For more information, visit our website www.nercon.com Check out our blog! Automatic Changeover Guide Rail Systems Changeover White Paper

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