1. M A Y - J U N E 2 0 1 4
J I M C O R R E L L
Line Two Time Study
2. Lost Production due to Downtime 4-5x Higher for Poly Film
Bags vs. Paper
Separate studies concluded an average of 1.10
tons/ hour of feed was not bagged due to downtime.
During the same time of day but using poly bags an
average of 4.35 tons/hour of feed was not bagged.
Average Time to Drop Bag by Grabber
Bag Type Poly Poly Paper Paper
Bagger Side Side A Side B Side A Side B
Worst Case 47 Seconds 37 Seconds N/A N/A
Best Case 4.5 Minutes 4 Minutes N/A N/A
3. Average of 60 lb./hr. of material variance while running poly
bags
If caught in time, most of the lost product could be
saved before falling off the line.
0
50
100
150
Dumped Bags Floor Scrap
lb
Rachael Ray 4 lb. (1-3 pm)
27 29
4. The Root Cause Analysis is based on identified gaps between
current machine capability and raw material selection
The current machines are not capable of efficiently
packaging poly based bags.
The bagger has issues with both the glossy surface of
the poly bags as well as the thin walls of the bags.
The thin walled poly bags contribute to a light weight
bag which increases machine malfunctions.
5. Top 3 Possible Solutions Provide Multiple Alternatives to
Tackling the Downtime
1. Resource Allocation
2. Machine Modifications
3. Poly Bag Redesign
6. Resource Allocation to the Line Will Mitigate the Effect of
Each Downtime Event
Add one employee to observe the EDL
Identify film breaks immediately .
Stop the line before causing a shutdown at the palletizers.
Add one employee to observe the
Conveyance/Former
Identify flared/poorly presented after forming and before
sealing.
Remove trouble bag from the line before causing a
jam/product falling from the line.
7. Machine Modifications Offer Potential Solution
to Downtime Issues
Correct suction cups for bag type.
Validate that we are using correct suction cup for bag type (Poly vs
Paper).
Set periodic replacement schedule (current cups look old).
Adding one more suction cup to grabber arm.
The arm currently has 3 cups, appears to be causing the poly bags to
crease on the in feed.
Leads to frequent bag drops, need to validate machine setup is correct.
Idea would be 4 symmetrically aligned cups, in addition to a back plate
to prevent bag folding.
9. Conveyance Modifications Offer Alternative Path Toward
Tackling Downtime Issues Related to Poly Bags
Side Rails to Hold Bags On Line.
Between bag former and sealer, to prevent bags from jamming due to
flared tops.
Turning down vibration on former if issues continue.
Machine vibration contributes to flaring of poly bag sides before
sealing.
Bagger Former Sealer
10. EDL Bundler Contributes to Up to 50% of Issue on Poly Bags
and is a major driver of downtime on all product SKU’s
Help operators understand why defects happen.
Maintenance/Machine Expert Root Cause Analysis does not match up with
Operator Capability
This leads to incorrect/insufficient solutions that cause recurring issues all shift
Recommend completing FMEA on EDL Bundler. Failure Mode Effects Analysis
Give them a clear process guide on how to fix problems that can
occur.
Per FMEA
Install a system to test integrity of bundles before they reach the
Mollers.
Bundles are breaking apart/ separating where film is sealed.
Bad bundles are up at Mollers in <30 seconds, operator walks 30-40 yards to
correct issue at Moller.
11. Poly Bag Redesign Offers Best Initial Opportunity to
Minimize Downtime on Poly Bags
Potentially changing the bottom of the poly bags and how they open.
Current bags are unstable on conveyance due to rounded bottoms.
The tops of current bags tend to flair open causing dumped bags.
Adding slightly more material to increase the wall thickness.
Higher mil plastic, increased bag thickness can improve bag
presentation in bagger and decrease effects of feed rounding out the
bag.
Poly
Thickness
Paper
Thickness
Paper bags
are 40%
thicker
than poly
About .005
in
About .0075
in
12. M A Y - J U N E 2 0 1 4
J I M C O R R E L L
Line Two Time Study
