Unfortunately, we still haven’t invented a cartoner, case packer, tray packer or palletizer that can work 24/7,
with no downtime. Our machines are built solid, but even the most reliable
machines occasionally need to be shut down in order to do maintenance and
replenish materials that the machines use. All managers strive to increase the efficiency
of certain processes. One of the ways to increase efficiency is to maximize the
automation processes and minimize downtime.
Key techniques for increasing efficiency
Start with gathering precise information about your
packaging line. This is how operators can analyze the efficiency of the line
and discover if there is a room for improvements. Engage the workers on the
factory floor in the process and you have a winning strategy. Stimulating your
employees to benchmark and analyze their performance will make them more
energized and willing to discover new ways to improve efficiency.
Changes to manufacturing practices can also create
efficiencies and increase throughput. One of the major causes of downtime is
material or product loading and utilizing an automatic loading system can
significantly reduce downtime and increase profitability. Automation of processes
often means that fewer operators can manage the task, which reduces the labor
costs.
There are two areas you should focus on in order to accomplish
a high degree of packaging automation uptime: redundancy and availability. Redundancy
is about backup systems that can take over the production during the
maintenance, servicing or failure of some of the main components. Without the
backup system,all these cases would end in system downtime.
Redundancy in Packaging Automation
Printer/applicators: These machines need a steady supply of
labels that come in large rolls. Instead of shutting down the operation when it
is time for a roll change, a second machine can take over the full production
load during maintenance. Actually in many cases, having two printers running at
the sametime enables a higher label application rate and actually works better
than keeping one machine as a backup, because it eliminates the time needed to
get the spare machine on line.
Packing list inserters: These machines require paper
replenishment, and depending on the air humidity, there is constant risk of
paper jams.This can be easily solved with 2 machines working side by side.
Availability in Packaging Automation
Availability is about the percentage of time the system
components are available for operation in comparison to the time they are not
(when they need to be turned off for maintenance or repair)
Some solutions are better than others when it comes to availability.
So,for promoting packaging
automation uptime, consider these solutions:
Use glue machines for carton sealing instead of
tape: Gluing the top and bottom of a carton saves money in materials, it can
improve the opening experience for your customers and it dramatically increases
uptime for your automated packing system as well. In order to replace tape
rolls the machine has to be shut down. Glue on the other hand is stored in a
reservoir that can be refilled while the machine is in operation.
·
Use machines with servo controls instead of VFD
driven or pneumatic machines: Servo controlled equipment requires less
maintenance and adjustment during operation and it is easier to change over
between sizes than VFD driven or pneumatic equipment because of preloaded
programs.
Increases in productivity and
efficiency result in increase in the profitability of the business. With
maximum line efficiency, each package is able to absorb more of the plant
overhead. The existing capital structure can be used to fulfill more customer
orders at less cost per unit. Relatively small but highly strategic capital
investments, such as automatic packaging equipment, can be returned quickly and
ultimately lead to even greater line profitability.
If you are looking for a way to minimize downtime and
increase efficiency, search no longer! Tishma Technologies manufactures fully
automated packaging machines and systems with various modular add-ons that
allow you to automate every aspect of the packaging process, from product
feeding to printing and labeling.
