In Part 1 we looked at the components of Overall Equipment Effectiveness (OEE) and how to calculate it. This formula works well for existing equipment and is an effective tool to improve the efficiency of an existing line. However, can this same formula be used to help in new equipment buying decisions? Is there a way to affect the various components of the OEE formula before the line is even established? Let’s review the OEE components: availability, performance and quality; and how the machine itself can impact those components.
The first component of the formula is availability. Typically, the most notable factors that impact Availability from a case packer standpoint are those that assist in eliminating downtime – whether that be planned downtime due to changeover and maintenance or unplanned downtime due to clearing faults.
From an availability standpoint, the overall focus is to keep the machine running in production as much as possible. However, what if the manufacturer were to add features to the machine to help reduce the overall downtime? Downtime may be inevitable, but the amount of time spent in that state can be reduced. Let’s review from a fault recovery, changeover and maintenance perspective.
While we understand that it is preferable to never have the machine breakdown, we know that ideal conditions will not always exist, and fault situations occur. An HMI ESTOP recovery map quickly directs the operator to the trouble area and reduces the overall time needed to clear the fault.
Overall red fault machine lighting increases the visual recognition of the machine’s fault status. This decreases the time that the machine sits in a fault status without it being recognized.
Both the fault map and machine lighting make it easier for the operators to identify and alleviate the problem or cause resulting in less overall downtime for the machine.
In a world where SKU’s seem to multiply for every product, the time needed to changeover from one pack pattern or SKU to another can significantly affect the overall OEE of a case packer. Changeover maps and tool-less changeover are two options that minimize downtime. All changeovers can be done without additional tools to insert or remove parts needed for one SKU to the other. The changeover map within the HMI also helps the operator make all necessary adjustments on the machine. These HMI Visual aids informs the operator what the set point needed at each changeover location.
In addition to the visual aids, electric changeover verification modules assist in quick changeover These modules are set for all changeover settings that do not require a parts change. The operator cannot start the machine without making the correct adjustments of the selected recipe. This prevents further downtime due to jams and product damage. Our studies have shown that these tools have created a changeover time of 20 minutes or less.
If customers are looking for an even shorter changeover time, automated changeover (for changeovers that do not require change parts) will provide the solution. This feature is powered by servos and can complete a full changeover in approximately 5 minutes.
The second component of OEE is performance. From a performance perspective, the biggest impact a case packer can have on OEE ensuring not to bottleneck production. A bottleneck will limit the overall line performance. During the design phase, it is essential that the to understand the planned and future products to be run on the line as well as the upstream surge capacity to ensure case packer performance can run at the same performance as the rest of the line.
The final component of OEE is quality. From an OEE perspective, it is not enough to just produce at a high rate for as many minutes during the shift as possible. The resulting product also needs to meet product quality standards. Two perspectives need to be taken into consideration to ensure peak quality. The first perspective is ensuring that the corrugate being used is not damaged in the packaging process. Case packers need to be gentle on your corrugate. An example of this is the M2000 case packer which uses top squaring fingers and bottom squaring flights. These capture the case at the top and bottom BEFORE compression is applied to ensure major flaps are squared up to the case during the sealing of the case.
Secondly, during design your OEM must work to ensure that the case is fully sealed at the end of the process. The gluing and compression areas are designed to better control of glue and manufacturers joints to ensures better adhesion.
As we saw in Part 1, OEE is a powerful tool to drive more efficiency throughout your plant and packaging lines. This same tool can also be used to help guide packaging equipment purchases, as the base design of the equipment can positively impact OEE. Understanding the amount of time machines need for fault clearing, changeovers and planned maintenance can also help to understand the machine’s impact on the availability portion of OEE. The design impact on performance really starts with a true partnership between the plant and the OEM to understand the true capacity required and the products planned for the line. Finally, safeguards built into the machine operation to help ensure the quality of the cases packed.
For a complete look at the M2000 side load case packer’s availability, performance and quality visit www.BrentonEngineering.com .