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Cost optimal development of processes for manual and semi-
automatic packaging systems
Developing the case company’s packaging processes
Bachelor’s thesis
Degree Programme in Mechanical Engineering and Production Technology
Riihimäki, autumn 2015
S.M. Rashed-Uz-Zaman Rokon
ABSTRACT
Riihimäki
Degree Programme in Mechanical Engineering and Production Technology
Design of Mechanics
Author S.M. Rashed-Uz-Zaman Rokon Year 2015
Subject of Bachelor’s thesis Cost optimal development of processes for manual
and semi-automatic packaging systems
ABSTRACT
The case company, * is one of the leading companies in Finland that sells
quality products to local and international markets. Some of the products
are repacked to smaller quantities from bulk amount such as *,*. One of
the challenges the company faces is how to increase the production rate of
repacking section without major investments in it.
The aim of the thesis was to find better solutions available in the market to
increase the production rate of the methods. If readymade solutions could
not be found then new working methods needed to be designed. Also, the
slowing factors of the repacking sections needed to be identified and
found better solutions trend to eliminate them. All the proposed solutions
were not to require very high investments.
During the thesis work, several tests on the present repacking machines
were conducted to find out the affecting factors of the processes. Brain-
storming for new working methods for several tasks was conducted with
the help of supervisors both from the university and *. Necessary proper-
ties needed to be kept in mind while finding solutions.
Based on the need and other affecting factors, an implementation of new
machines was proposed. A new kind of precise counting machine was
found to eliminate manual counting problems. A new type of simple but
fast packaging box for products was also proposed instead of the present
more complex packaging. For manual packaging, a new design of a work-
ing table was modified. All the proposed solutions were expected to in-
crease the current production rate and to make the process easier without
investing much in it.
The public version of the thesis does not include any confidential infor-
mation about the case company and the information was either opted out
or star marked for maintaining confidentiality.
Keywords Packaging, counting machine, box maker, labeling
Pages 39 p. + appendices 1 p.
Contents
1 INTRODUCTION ....................................................................................................... 1
2 BACKGROUND RESEARCH ................................................................................... 1
3 DESCRIPTION OF THE CASE COMPANY AND THEIR PACKAGING
PROCESSES .................................................................................................................... 2
3.1 Hand repacking process ...................................................................................... 3
3.2 Semi-automatic repacking process ...................................................................... 4
4 CHALLENGES TO BE SOLVED .............................................................................. 4
4.1 Manual and slow counting problems .................................................................. 5
4.2 Complicated packaging box ................................................................................ 6 4.3 Manual and slow labelling problems .................................................................. 6 4.4 Manual palletizing problems ............................................................................... 6
5 POSSIBLE SOLUTIONS FOR OVERCOMING THE CHALLENGES ................... 6
5.1 Introducing a new type of packaging boxes ........................................................ 7 5.1.1 Reasons behind the new packaging box .................................................. 8
5.2 Different types of counting machines for dry products....................................... 8 5.2.1 Cup fillers ................................................................................................ 9 5.2.2 Auger filling machines ............................................................................ 9
5.2.3 Net weight based vibratory filling system ............................................. 10 5.3 Choosing the best counting method for the case company ............................... 10
5.3.1 Reasons behind choosing the net weight based filling method ............. 11 5.4 Different types of labelling machines ............................................................... 13
5.4.1 Stamp on flat surface labelling machine ............................................... 13 5.4.2 Wipe down labelling machine ............................................................... 14
5.5 Choosing the best labelling machine for the case company.............................. 15
5.6 Robots for palletizing ........................................................................................ 16 5.6.1 Reasons behind choosing robots for palletizing .................................... 16
6 DEVELOPMENT OF A SEMI-AUTOMATIC PACKAGING MACHINE ........... 17
6.1 Installing a box maker to the production line .................................................... 17 6.1.1 Reasons behind introducing box making mechanism ........................... 21
6.2 Installing a new and more accurate net weight based counting machine .......... 21 6.3 Installing a labelling machine to the production line ........................................ 22 6.4 Installing a robot for palletizing ........................................................................ 23
6.5 Complete layout and required time ................................................................... 24
7 DEVELOPING THE MANUAL RE-PACKAGING SECTION .............................. 25
7.1 Precise counting machine for the hand repacking section ............................... 25 7.2 Installing a moving product holder into the new working table ....................... 28 7.3 Using a counting scale with more capability of weighing ................................ 30
8 INVESTMENT RETURN ......................................................................................... 30
8.1 Manufacturing costs .......................................................................................... 30 8.2 Investment return calculation for semi-automatic repacking machine ............. 31
9 RESULTS .................................................................................................................. 33
9.1 Efficiency improvement for the semi-automatic repacking process ................. 33 9.2 Efficiency improvement for the manual repacking process .............................. 34
10 RECOMMENDATIONS .......................................................................................... 34
10.1 Using flat boxes for longer products ................................................................. 34 10.2 Installing two computers close to the working area during summer ................. 35 10.3 Repacking into small bags................................................................................. 35
11 CONCLUSION ......................................................................................................... 37
SOURCES ...................................................................................................................... 38
Appendix 1 Contact details of related companies
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
1
1 INTRODUCTION
These days, packaging industries around the world are mostly handled by
fully automatic or semi-automatic machines and also manually. There are
different types of machines that perform the packaging job but yet there is
still a great barrier as the investment for an accurate packaging machine
for various products is quite high. So, using a very expensive machine for
smaller production quantities is not really worth the investment. The case
company, * has semi-automatic and manual packaging systems with the
same problems as stated above. The product variety is so high that it is not
possible for a single machine to cover all of them. That is why the tasks
are divided and sent to the ‘Hand Packaging’ section or to the semi-
automatic machine or sometimes to the fully automatic machine. This al-
ways depends on the product properties and production quantity.
The objective of the thesis project was to improve the present repacking
processes by redesigning the current process layout, by carrying out a
market research for other cost effective packing machines and by design-
ing the working methods for a new customized working table for low in-
vestment. The expected results of the thesis work will be handling more
task in short time, improving the packing section’s efficiency and decreas-
ing the production cost for packaging without investing much in it.
Based on the test results carried out during the thesis project, possible so-
lutions were proposed to develop the current packing process. A totally
different type of packing box sample was given to the company to elimi-
nate the complexity present packing box’s complexity. During the market
research, several counting machines were found which could solve the
present manual counting problems. An automatic labelling machine and
palletizing machine were also found to make the whole process faster.
Several other developments were also proposed.
2 BACKGROUND RESEARCH
Packaging is one of the most important issues for companies as it repre-
sents the quality of the company and its products most of the cases. It is
the enclosure for any kind of product that we use in our everyday life. De-
pending on the product varieties, packaging can be done in plastic bags,
cardboard packets, cans or plastic bottles and in many other things.
The case company usually deals with * and they have a repacking section
for small * that they buy a bulk amount from different sources. This re-
packing is done to cardboard boxes by hand or by semi-automatic ma-
chines. During the repacking, the product counting part is done manually
which takes a long time. Other tasks such as labelling and palletizing have
also been manual till now and that is why the whole process is not as fast
as expected.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
2
This thesis work focused on finding out the slowing factors to the process-
es and on trying to find out better working solutions for repacking. To do
that the author needed to work in these sections personally to get the actu-
al insight of the problems. Based on the reasons found, several readymade
solutions were found from the market and some other ideas for performing
special tasks were introduced. Products from different companies were
studied to find the best solution to specific needs. Some other works of re-
search in the same field were also studied to get new ideas for the solution.
Currently, 50% of the repacking is done through a worker-machine system
but with the proposed solutions, 100% of the task will be done by this sys-
tem (Groover 2008, 21). The human worker will perform the jobs with the
help of machines that will take care some of his tasks. This is one of the
most common manufacturing systems around the world.
3 DESCRIPTION OF THE CASE COMPANY AND THEIR
PACKAGING PROCESSES
* is one of the leading companies in Finland selling various types of * .
They have a good reputation for providing quality products to meet cus-
tomers need.
The company buys quality products from both local and foreign suppliers.
Most of the items are sold to the market as it is bought from other suppli-
ers. Some items come in a bulk quantity which needs to repack in the
warehouse in small quantities for selling. To repack these products, the
company has a repacking section. Based on the product properties and
batch size, products are sent to the hand repacking, the semi-automatic
machine repacking or to the small bags repacking section.
Although both the hand repacking and the machine repacking are going
well but still there are some challenges. The semi-automatic repacking
machine that the company has, cannot count products precisely and the
tolerance is high. Production rate difference for both processes is not that
high. Some items cannot be counted by counting machines at all. Packers
need to make packets and put labels manually which slows down the pro-
cesses.
This thesis work concentrated on finding out new ideas for the develop-
ment of both the hand repacking and the semi-automatic machine repack-
ing processes. The objective was to increase the production rate by making
the process faster with the help of possible changes. To find out the solu-
tions, the difference between these two different processes needed to con-
sider.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
3
Two different types of repacking processes will be discussed below to give
an insight to the readers. The following figure shows different types of
products that are being repacked. As seen in figure 1, it is clear that the
shapes and sizes of different products vary each time. This needed to con-
sider carefully while finding out the solutions for packaging.
(Picture was not included for the public version)
Figure 1 Different types of products that are being packed in the case company
3.1 Hand repacking process
For oddly shaped products or for a smaller production quantity, products
are sent to hand packaging station. Sometimes, there are some products
which only require changing the labels. These are also sent to the same
section. There are different sized packets, generally called * boxes, are be-
ing used to pack the products. The boxes are numbered according to their
sizes for example * . Boxes are chosen based on the product properties,
the volume of the product and capacity. For example, hundred pcs of *
might fit the number *, so in that case, number * will be used but if five
hundred pcs of * need to be packed, then a bigger box number will be
used. Products are kept in the container and packer needs to pull the prod-
uct by hand or with the help of a tool to put it into the box. Under the box,
there is a weight scale, which measures how many pieces are there in the
packet. Thus, the packer pulls products until getting required number.
Generally, products are sent to hand repacking if the production quantity is
less than one hundred fifty boxes. It depends on other variables too but if
the production quantity is higher, then they are sent to the semi-automatic
repacking section. The average production rate for hand repacking section
is sixty boxes/per hour/worker, but it always depends on product proper-
ties and other variables such as box sizes, products etc. The figure 2 shows
different types of boxes. The sizes of the packets are defined by numbers
according to their measurements such as * and so on. The white boxes are
being numbered as * .
(Picture was not included for the public version)
Figure 2 Different types of packets that are being used currently
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
4
3.2 Semi-automatic repacking process
As mentioned, if more than one hundred fifty boxes are to be made; this is
usually done by the semi-automatic machine. Unlike hand repacking,
smaller sized products, for example, * etc are repacked here. There are
several vibrating containers that hold the products and feed them slowly to
get the required weight. For that reason, oddly shaped products cannot be
put there. The same types of boxes are used here too. The machine is pro-
grammed to vibrate and feed the products to a container having a weight
scale until it reaches the required weight. The required weight is given be-
forehand according to the quantity. For example, if hundred pcs of * need
to be packed, with the help of a weight scale, the mass of ten pcs of * is
measured and this information is recorded to the computer of the machine.
After that, the machine automatically calculates the required weight for
hundred pcs of *, but a tolerance is also given to the machine, usually 3%.
When the weight in the scale is in between the tolerance level, vibrating
containers stop feeding the products and drop them into the box. This way,
the worker always gets more or less hundred pcs of * into the box and then
the packer needs to add some more or take some of the * away to make the
quantity precisely hundred. The machine is designed in such a way, that all
the vibrating containers stop when it reaches the tolerance level, that is
why the machine is never precise and a human worker always needs to ad-
just something. The only way the machine helps the worker is that the
boxes already contain close to the required number of products dropped by
the machine. So, this saves a little bit of time. The average production rate
for the semi-automatic packaging machine is hundred boxes/per hour con-
sidering that one person is working at the machine. Figure 3 shows the cur-
rent semi-automatic repacking machine.
(Picture was not included for the public version)
Figure 3 Current semi-automatic repacking machine
4 CHALLENGES TO BE SOLVED
The current repacking process for the semi-automatic and manual repack-
ing system includes quite similar tasks. During the manual repacking pro-
cess, a packer needs to perform the following tasks:
I. Making the base and outer shell of the package ready (as the pre-
sent packet has two different parts)
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
5
II. Weighing the products with the help of a weight machine and ad-
justing for precise quantity
III. Closing the lid and tie with a scotch tape
IV. Putting a label on top of the packet
V. Palletizing the packet
Different tasks require a different amount of time. A test was carried out to
determine which task requires most of the time. For the test, eighty pack-
ets were made, twenty packets in each test. During the test, time for task
III and IV is calculated together. The test result was shown in table 1.
Product: *
Packet number: *
Number of packets: Eighty pcs, twenty packets in each tests
Table 1 Duration of different tasks during manual repacking
Time required for making 20 packets (in seconds)
Tasks 1st test 2nd test 3rd test 4th test
Making packets ready for
weighing products
120 s 115 s 105 s 125 s
Weighing for precise amount 660 s 620 s 610 s 570 s
Closing the lid and labelling 125 s 120 s 115s 110 s
Palletizing the packets 55 s 45 s 47 s 55 s
Total time required 960 s 900 s 877 s 860 s
From the test results, it was clearly seen that weighing products and adjust-
ing it for precise quantity took the longest time. It was also clear that the
total time for performing a specific task was decreased as the worker got
used to with the process.
4.1 Manual and slow counting problems
Currently, weighing products for precise quantity are done totally manual-
ly by human workers. For the semi-automatic packaging process, it is half
done by the machine as stated earlier. The machine tries to put a closer
quantity to the required one. The human worker needs to adjust the rest for
precise quantity. As weighing products for precise quantity took the long-
est time, it will make the process much faster if this time can be mini-
mized. So a precise product counting machine needed to be found.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
6
4.2 Complicated packaging box
Although, in this test, * white box was used which takes around six sec-
onds to make, the other boxes, known as * box, also take around six sec-
onds to make. Closing the lid and labelling the box also require around six
seconds for each box. This means even if the box was changed to another
one, the test results remain the same. The * boxes have two different parts
as shown in figure 2 and joining these two parts together takes around six
seconds. This task slows down the repacking process. So a new kind of
packaging box needed to be found from the market or to be designed.
4.3 Manual and slow labelling problems
Presently, labelling is done manually which requires a lot of time. Alt-
hough it seems labelling does not take that long time but when it comes to
the question of labelling one thousand packets a day, the required time is
really high. There are plenty of labelling machines available in the market
which can replace the need to do this task manually. In that case, the label-
ling time can also be saved too. So a suitable labelling applicator needed to
be found from the market which could be installed with the existing pro-
duction line.
4.4 Manual palletizing problems
At present, palletizing is done totally manually which is not a quite fast
process. For palletizing packets, low budget articulated robots can be used.
These robots are easy to program and can remember thousands of products
data for palletizing. But as it was seen from the test results that palletizing
took comparatively shorter time than other tasks, this needs to consider
that if a robot is really worth of the investment.
So, the challenges needed to deal with were:
I. Finding a counting machine for measuring precise quantity
II. Developing a simpler and faster packaging box.
III. Replacing the manual labelling process for the semi-automatic ma-
chine
IV. Replacing the manual palletizing
5 POSSIBLE SOLUTIONS FOR OVERCOMING THE CHALLENGES
The affecting factors of the repacking process were already discussed. To
find the solution, several things were taken into consideration such as the
company’s product types, production quantity, and investment possibili-
ties. Based on that information, the following solutions were proposed for
further consideration.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
7
5.1 Introducing a new type of packaging boxes
As stated, the present * boxes have two different parts which need to put
together for repacking. This takes around six seconds and sometimes it is a
little bit difficult to join them together. To remove that problem and make
the process faster the following type of box having only one part can be
used. This type of box is very easy to prepare for filling products and clos-
ing the lid. Making the packet ready for filling products will take only one
second. Time for filling the product into the box depends on product prop-
erties. Closing the lid and labelling might take three more seconds. Alto-
gether, without considering the filling time, this type of box will be ready
in four seconds whereas the previous one would take six seconds just to
get ready for filling products. Closing the lid, taping the lid and labelling
take another six seconds or sometimes more. So without considering the
filling time, the present packaging box takes at least twelve seconds to get
ready whereas this new type of boxes will take four seconds only. Thus
twice as much as time can be saved and make the process 200% faster just
by changing the current packaging. Table 2 shows a comparison between
the two boxes based on the time saved for different tasks.
Table 2 A comparison based on the duration of different tasks with new boxes to the
present * boxes
Present * box New kind of box Time saved
Duration of making the
packet ready
6 s 1 s 5 s
Duration for closing
the lid and labelling
6 s 3 s 3 s
Total time 12 s 4 s 8 s
Figure 4 shows the new kind of packaging box that can replace the present * boxes.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
8
Figure 4 New kind of packing box having only one part
5.1.1 Reasons behind the new packaging box
The new packing box will serve as follows:
Only one part inside the package
Easy to get ready for filling products
Easy to close the lid and no tape required
Strong and stable, no problem during transportation
High wall thickness, so the product inside is safe
Easy to automated if needed
The whole packaging takes only 4s to be ready while the present
one takes twelve seconds without considering the weighing time
Reliable method of packaging
Comparatively low-cost but faster packaging
A little bit customization needs to do with this box as it does not have any
window like the present one to see the products inside. Also, the compa-
ny’s brand name has to be printed in all the side walls so it looks as good
as the present * boxes. These transformations will not be difficult to make
but after that, the box will serve better than the present one.
5.2 Different types of counting machines for dry products
Currently, product counting is done manually in hand repacking section
and in semi-automatic repacking, half of the job is done by machine. The
semi-automatic machine is quite old and cannot measure actual quantity.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
9
Hence, the human worker needs to adjust it which takes time. There are
plenty of modern counting machines available in the market which can re-
place the system. This kind of machines uses different processes to count
the products depending on the product properties. Some of the counting
machines available in the market and their working principle will be dis-
cussed below.
5.2.1 Cup fillers
Cup fillers are suitable for a free flowing product such as powders, liquids
or other granular products. The basic working principle of this kind of fill-
ing machine is dipping the measurement cup into the product and then
presses it straight ahead to the packaging. The hopper is situated generally
above the cup. Figure 5 shows a common cup filler machine.
Figure 5 Common cup filler with a hopper and a piston (Cup Fillers, 2015.)
One of the problems with this kind of filling system is, they are not suita-
ble to measure a different amount of products quickly as changing the cup
requires long time or sometimes it is not even possible. So the versatile
uses of this machine are restricted.
5.2.2 Auger filling machines
This specific type of filling system is also suitable for granular, powdered
and liquid products. The working principle is a bit different than the above
mentioned one. This type of machines usually dispenses a predetermined
amount of product of weight to the packets or boxes or in any other pack-
aging. The accuracy can be +/-1% for the counting.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
10
Figure 6 Auger filling machine for fine products (Auger Filling Machine, 2015.)
There are some drawbacks of this kind of filling system such as they are
so compact hence suitable for very fine products only. If frequent product
changing is needed, this type of machine will require a lot of time for that.
5.2.3 Net weight based vibratory filling system
This type of filling system is quite popular for their variety of usage and
flexibility. The basic working theory is, there is a container where the bulk
amount of products will be kept. There is a vibrating rotor which vibrates
and feeds products to a weight scale container. The machine vibrates in a
uniform speed as long as it reaches to 90-95% weight and then vibrates
slowly as long as it makes 100 %. After that, the container opens to drop
the products into boxes, bags etc. Another counting cycle begins then.
5.3 Choosing the best counting method for the case company
Even though there are plenty of counting machines available in the mar-
ket, not all of them are suitable for the case company. The product variety
is really high and their shapes, sizes vary each time. The products are dry
and they are basically hardware items so cup filling and auger filling
methods are not so suitable for them. According to the company’s need,
net weight based vibratory filling method seems the best solution.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
11
5.3.1 Reasons behind choosing the net weight based filling method
Precise counting which is the most important issue
Can handle various shapes and sizes of products
Machine constantly learns to optimize the precision
Easy to combine with existing production line
Very compact, less space required
Easy to control and can remember previous settings
Possible to customize the machine for individual needs
Saves counting time as no adjustment needed
The following vibratory machines were chosen as possible solutions for
the company.
A) S-6 Cascading style net weight filling System:
This specific model of a net weight based counting machine has good ac-
curacy for counting applications. There are two different vibrating feeders
in this; the 2nd one vibrates faster than the first one, giving the machine a
dribble feed for more accuracy. With this machine, most of the products
that the company needs to pack every day can be handled with a great ac-
curacy. Figure 7 shows the specific model of the S-6 cascading style net
weight filling system.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
12
Figure 7 S-6 Cascading style Net weight Filling System (S-6 Cascading style Net
weight Filling System, 2015.)
Some specifications of this product are:
Very compact and not too heavy
Tolerance is as low as 0.1%
Can count a variety of shapes of products
Possible to integrate the system with bags or boxed in the produc-
tion line. (Busch Machinery, 2015.)
S-6 price information: Around €10000 for the basic system. This machine
has to be integrated with the present conveyor system so that will cost
more for the installation.
B) Model VF200-HDXvibratory filler:
This specific model from ALL FILL has a twin lane to feed products and
it works in the same way as the previous one. It has a large hopper and
two 16inch wide vibratory lanes. The weight bucket has a capacity of
counting 8 fills/minute and its maximum weight can be twenty two kg.
The accuracy varies from 0,25% - 0.5% depending on the products and
quantities. Figure 8 shows the model VF200-HDXvibratory filler system.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
13
Figure 8 Model VF200-HDX counting machine (Model VF200-HDX vibratory filler,
2015.)
There are some differences between these two machines stated above. The
later one has two vibratory hoppers instead of one as the first one. So, in
some cases, model VF200-HDX can be faster than S-6 counting machine.
S-6 is more suitable for smaller products and amounts.
VF200-HDX price information: Around €15000for the basic system. Ad-
ditional customization will cost more.
5.4 Different types of labelling machines
Labelling the ready packets is now being done by hand both in hand pack-
aging and semi-automatic hand packaging processes. Compared to the
other process, labelling takes less time. As it turned out from the test, la-
belling for twenty packets needs only around twenty seconds or less. In
hand repacking section, products are changed frequently as only small
production quantity, for example, twenty packets or more comes here. As
the products are changing frequently so do the label also. That is why it is
not cost effective or time effective to introduce a labelling machine for
that small product number. By hand, it will be much faster than a machine
to label only twenty packets or a little more. But when it comes to the
semi-automatic machine, the batch size is much larger than the hand pack-
aging. This takes a long time to label. So a labelling machine for flat boxes
can be introduced there. As the product changes frequently, the company
needs a print and apply label applicator to serve their purpose. There are
different types of labelling machines available in the market which are
discussed below.
5.4.1 Stamp on flat surface labelling machine
This kind of labelling machine prints and applies the label from the top of
the flat box as a stamp. The labeller is equipped with a pneumatically con-
trolled piston which moves up and down to apply labels. Depending on the
model, they can print any size and kind of labels on different heights of
boxes. One of these kinds of labelling machines is discussed briefly in the
following. Figure 9 shows model 252 labelling machine.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
14
Figure 9 Model 252 print and apply labelling system with adjustable height (ID tech-
nology, 2015.)
This smart and adjustable print and apply labelling machine is ideal for the
task. This can be integrated with the present conveyor system and depend-
ing on different sizes of packets; it can change its height. So there will be
no setup time for labelling. The information for different products will be
given by a computer and then the printer will know what to print. This is
specially designed for flat surfaces and as all the boxes has a flat surface,
this is an ideal solution.
5.4.2 Wipe down labelling machine
There is another kind of labeller available in the market known as wipe
down print and apply labeller. This works a little bit different way than the
above mentioned one. This one dispenses labels through knife peeling sys-
tem. This is also possible to integrate with the present production line and
applicable for different heights of packets. Some technical features of one
of these kinds of labeller are mentioned briefly below.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
15
- Easily adjustable heights
- Different sizes of label can be printed
- Good choice for labelling flat head boxes. (E-packing S.r.l., 2013.)
Figure 10 shows the URANO SPT labelling machine.
Figure 10 URANO SPT Printers Desk print and apply label applicator (E-packing S.r.l.,
2013.)
5.5 Choosing the best labelling machine for the case company
Both types of labelling applicators discussed above are suitable for the
case company as they have only flat head boxes to label. The reasons be-
hind choosing this type of label applicator are:
Fast and precise labelling application
Adjustable to various heights and widths if needed
Can be easily installed with present production line
Can print different sizes of labels if needed
Easy to input information about product changes
Saves labelling time
Price information for labelling machines: Depending on the application
and adjustability, the price can go from €3000- €5000 for this kind of la-
belling solutions.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
16
5.6 Robots for palletizing
As like as labelling, palletizing also do not take that long time at all. As
for hand packaging, the product changes so frequently, so it is quite fast
and convenient to do the palletizing by hand. For semi-automatic packag-
ing, around fifteen hundred packets are handled every day. Every batch
size is one hundred fifty packets or larger. This takes some extra time for
the packer to palletize the packets to the pallet. If a palletizing system,
preferably a basic robot is introduced for palletizing, this extra time can be
saved and the packer can concentrate on other tasks. Most of the packets
that are packed in the company do not exceed more than ten kilograms.
According to the need, the following articulated pick and place robot was
chosen for the palletizing task. Figure 11 shows the specific robot model.
Figure 11 Model UR10 pick and place robot for palletizing (Direct industry, 2015.)
Some specifications of the robot:
Type: articulated
Number of axes: 6-axis
Function: pick and place with precision
Payload: 10 kg
Reach: 1300 mm. (Direct industry, 2015.)
5.6.1 Reasons behind choosing robots for palletizing
Faster palletizing
Cost optimal development of processes for manual and semi-automatic packaging sys-
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17
Pick and place application can be carried out for different shapes
of boxes
Variable picking jaws
Able to pick up to 10 kg which is quite acceptable
Can be integrated at the end of production line to increase produc-
tivity
Saves palletizing time
Price information of palletizing robots: Depending on the brand and pay-
load capability, pick and place robots will cost around €20000- €30000.
Installation and programming are not included here. The full installation
might take €50000. As palletizing takes the lowest amount of time while
repacking, investing money on palletizing robots is only recommended
when production rate increases.
6 DEVELOPMENT OF A SEMI-AUTOMATIC PACKAGING
MACHINE
The present semi-automatic packaging system that the company has now
consists of a conveyor belt for feeding the packets and a vibratory contain-
er system to weigh the products for counting. For the presently installed
system, a packer needs to do the following tasks by himself continuously:
I. Making packets base ready for filling the products
II. Adjusting the precise amount in the packet
III. Making the outer shell of the packet and insert it into the base
IV. Closing the lid and taping the packet
V. Labelling the packet
VI. Palletizing the ready boxes
Except these tasks, the packer needs to bring the pallet filled with prod-
ucts, setup the machine for weighing, fill the vibratory container with
products and solve any other problem that arises during the process. Some
of the above-mentioned tasks can be replaced by the automated system so
that the packer will have more time to do other tasks, which will make the
job much faster than now.
With the presently installed systems, the production rate is around 100
packets/ hour depending on the product properties. The following devel-
opments can be introduced to the system to increase the production rate up
to 150% at least.
6.1 Installing a box maker to the production line
The presently installed system has a manual box feeding mechanism. The
packer presses the box bases to the conveyor and then they stop under the
weight scale where the container drops the products after counting. After
that, it follows the conveyor to the packer and the packer adjusts the pre-
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
18
cise quantity in the box. The weighing machine weighs around 4-6 packets
per minute and packer needs only a couple of seconds to make it ready for
filling the products. Is does not seem long but for fifteen hundred packets
a day, the time is quite high. Not only that, the packer needs to move every
time for doing the task. As the machine runs all the time, more boxes get
prepared by the machine for the packer, during the process. If the packer
would not need to do it all, a handsome amount of time will be saved here
which he can put for other tasks. As a new kind of packet is already pro-
posed, the following mechanism is designed for an automated packet feed-
ing. The box making mechanism will have two different parts.
a) A box feeder and
b) A box opener
a) Box feeder: This mechanism will be responsible for feeding flat boxes
that are supplied. A packer will put the flat non-opened boxes on the con-
veyor belt of the feeding mechanism and the belt will move slowly for-
ward to the box opening mechanism. The feeder and opener will be syn-
chronized so that the conveyor will move forward when needed. There
will be two rods in each side of the conveyor belt to adjust the width of the
conveyor with different sizes of packets. A pushing bar will hold the
packets and push forward as it approaches the box opener. The box feeder
will look like the figure 12.
Figure 12 Box feeder mechanism
Cost optimal development of processes for manual and semi-automatic packaging sys-
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19
b) Box opener: The box opener mechanism consists of two main parts.
One of them is a pneumatic cylinder. This cylinder will be controlled with
pneumatic pressure and will be able to move forward and backward. This
mechanism will hold a box opener along with suction cups at the end of it.
The box opening mechanism will be connected to the cylinder such a way
that the movable jaws can move freely. The suction cup holder has two
jaws that can move from zero degree to one hundred eighty degrees. This
suction cup will stay at one hundred eighty degrees while catching the
non-opened boxes from box feeder. The suction cup will then grab a box
by sucking it and cylinder will shrink towards the conveyor. In this mo-
ment, the jaws of the box opener will move from one hundred eighty
degrees to ninety degrees while sucking the right angle sides of the box.
Because of this movement, the unopened box will be opened and then the
suction cup will release the box to the conveyor. After that, it will repeat
the same process for the next packet.
Figure 13 shows the movable jaws along with suction cups of the box
opening mechanism.
Figure 13 Movable jaws along with suction cups for holding and releasing boxes
Figure 14 shows the pneumatic cylinder of the box opening mechanism.
Cost optimal development of processes for manual and semi-automatic packaging sys-
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Figure 14 Pneumatic cylinder to move across the conveyor with suction cup holder
Figure 15 shows the complete box opening mechanism.
Figure 15 Box opening mechanism
The whole mechanism will look like figure 16.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
21
Figure 16 Placement for box making mechanism
6.1.1 Reasons behind introducing box making mechanism
The mechanism will save a lot of time for box opening
This can be 99% effective while opening boxes
Faster and precise box opening mechanism
Less complicated method
Easy to change the heights and widths for variable box sizes
Price information for this mechanism: As this mechanism has to be cus-
tom made so it is hard to calculate the cost of such mechanism. The cost
will entirely depend on the manufacturer of this mechanism. An estimated
cost for this mechanism can be around €5000- €8000.
6.2 Installing a new and more accurate net weight based counting machine
The present weighing scale in the semi-automatic machine is not able to
count and drop exact amount of product into the box. The machine is old
and so does the process. Based on the mass of the required product and
quantity, the vibrating container starts vibrating till it reaches close to the
required mass. There is a tolerance (generally 3%) given to machine so
every time the machine reaches to the tolerance level, all the containers
stop vibrating and drops products into boxes. This way the box never gets
the exact amount of products. The tolerance level is sometimes big or
sometimes small, depending on the products and other operating variables.
Cost optimal development of processes for manual and semi-automatic packaging sys-
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Because of this, the packer always needs to adjust the correct amount of
products in the box which takes quite a long time. If this process can be
eliminated, almost half of the packaging time can be saved as it is seen
from earlier test results that weighing and adjusting the correct number
take longer time than other processes. There are plenty of modern net
weight based counting machines which can count an exact number of
products with a slight tolerance (usually 0.1-0.5%) level which is quite ac-
ceptable for packaging process. This type of machine has a vibrating con-
tainer which can control its vibration by itself and has a connection with
the weighing scale. The container vibrates uniformly as long as it reaches
to 90-95% of required weight and then vibrates slowly as it goes close to
the required weight. Once it reaches the required weight, the container
stops vibrating and the scale drops products into boxes or something else.
The company has a large variety of products that need to be packed, but
not all of them can be put into this type of machine. The replacement of
counting machine in the present production line will look like the figure
17.
Figure 17 Setup for precise counting machine along with the existing conveyor
6.3 Installing a labelling machine to the production line
Currently, labelling for the semi-automatic packaging process is done by
hand. As there are plenty of labelling machines in the market, if a labelling
machine is introduced in the process, the packer will have one less job and
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
23
can save a lot of time. As it already discussed above that the batch size in
the semi-automatic repacking section is usually two hundred or more so a
basic ‘print and apply’ labelling machine can be added here. As different
packets have different sizes and heights, the labelling machine has to have
a mechanical function so that it is possible to move it up or down accord-
ing to the needs. It will be connected to a computer where packer will give
the required information to the labelling machine telling what to print. All
a packer needs to do is, after closing the lid, leave it for the labelling con-
veyor to be labelled. Figure 18 shows the production line with the label-
ling machine.
Figure 18 Production line along with a print and apply labelling machine
6.4 Installing a robot for palletizing
At present, around fifteen hundred packets are produced by a packer in
each day considering 2 working shifts. Even though it does not seem tak-
ing quite a long time, but for a batch like fifteen hundred, it is a huge
amount of time. If a new kind of packet is used and other developments
stated above are applied, then the batch number will be bigger than fifteen
hundred. So the packer will need to put a lot of time for palletizing too.
But with the help of a very basic robot, this task can be eliminated and the
packer will have spare time to concentrate on other tasks. The robot can be
pre-programmed for different kinds of products so the packer does not
need to program it each time. The palletizing robot will be able to remem-
ber a variety number of products information to its memory and use it eve-
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
24
ry time for palletizing. If new kind of product comes, then the packer can
put necessary information for the robot from a computer program. A sim-
ple pick and place program can be introduced here and this way the packer
will save some time. Figure 19 shows a representation of the layout with a
robot.
Figure 19 Production line with a pick and place robot at the end
6.5 Complete layout and required time
After putting all the proposed developments together stated above, the
packer has to do only one task himself among those six different tasks
stated earlier. The task is number four, which is closing the lid for the new
type of packet as the process will get much more complicated if a machine
is introduced to do the same job. Although the packet is supposed to be
closed manually but in future, if the production rate goes higher, then a
closing lid mechanism for boxes can also be introduced. With the current
layout, the packer will have only one task instead of six tasks and can save
a lot of time. In the real case, the production rate will vary definitely but if
it is considered that the counting machine counts three packets per minute,
then an estimated value will be: one hundred packets per hour for the
semi-automatic machine which is 80% higher than the present one.
To calculate manufacturing lead time, following equation is used:
MLTj = ∑ (Tsuji + QjTcji + Tnoji)noj
i=1 (6.1)
Where, MLTj = Manufacturing lead time for part or product j(min)
Tsuji = Set-up time for operation i (min)
Qj = Quantity of part or product j in the batch
Tcji = Operation cycle time for operation i (min/unit)
Tnoji = Non operation time for operation i (min)
i= 1, 2, . . . . , noj (Operation sequence in the processing)
A simplified equation will be MLT= no(Tsu + QTc + Tno) (6.2)
Cost optimal development of processes for manual and semi-automatic packaging sys-
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Where noj=no which defines the number of machines. (Groover 2008,71.)
For example, a certain product is to be packed one thousand units. The on-
ly one operation taken into consideration here is the counting time. Aver-
age setup time for each operation is 0,1 hour/operation and average opera-
tion time is 0,005 hr (about twenty seconds for filling the packets by
counting machine). Average non-operation time due to handling delay and
other issues is 0,25 hour.
So, the required manufacturing lead time is (from Eq. 6.2)
MLT = 1 (0,1+1000*0,005+0,25) = 5,35 hours or around 320 minutes.
If the lowest efficiency is taken by the machine which is one hundred
eighty packets per hour, around 5,5 hours is needed to manufacture them.
So the result is quite closer to the calculated result here.
7 DEVELOPING THE MANUAL RE-PACKAGING SECTION
Products that come to hand repacking section vary in shapes and sizes.
Some products are so big and odd in shape that it is not possible just to put
them in a machine for automated counting process. As it is discussed sev-
eral times above, that during the repacking process, weighing products
takes the longest time; a similar counting process like semi-automatic re-
packing can be introduced here. This will save some time for the packer.
Sometimes, there are some odd shaped products that cannot be put in this
kind of machine; they can be done manually as they are being done now.
Some jobs do not need to be repacked, as they have already right amount
of products in the box. They only need the labelling and the packet to be
replaced. Recommended developments for hand repackaging section are
discussed below.
7.1 Precise counting machine for the hand repacking section
Details about net weight based counting machine are already discussed
above. A similar type of counting machine can replace the present count-
ing machine. The counting machine can be both precise and non-precise.
If the machine is precise and can count exact amount of products, then it
will take a little longer for the machine to count. Generally, this kind of
machine can count 3-6 packets per minute depending on the products and
quantity. If the machine is not precise and can only count a closer amount
required, then the process will be a little bit faster. In both cases, the pack-
er will save some time that he needs to weigh product now. This spare
time is possible to put on some other tasks which will make the process
faster than now. Figure 20 shows a representation of a new counting ma-
chine.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
26
Figure 20 Precise counting machine for faster counting
Along with the previous mentioned weighing machine, the following men-
tioned machines can also be introduced with the present manual working
table. Depending on the products to be packed in manual parking section,
the following two machines were chosen for the task.
A) Model VF100-BF vibratory filler:
This model has an ability to count up to twenty two kg and has twelve-
inch wide feeding pan. The hopper is five cubic feet which can accommo-
date a lot of products. This model is suitable for packing heavy products
and the accuracy is +/- 0,25%-1%. The only drawback with this machine
is, it can fill only 2 boxes/minute. Figure 22 shows the model VF100-BF
vibratory filler.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
27
Figure 21 Model VF100-BF vibratory filler counting machine (Model VF100-BF vibra-
tory filler, 2015.)
B) Model VF100-ST vibratory filler:
This is a basic level linear net weight machine. It has a one cubic foot
hopper and four-inch wide feeder pan. This machine is faster than the up-
per one and is suitable for small sized products. It can count 10 pack-
ets/minute and the accuracy is +/- 0,5%-1% . Figure 22 shows the model
VF100-ST vibrating filler.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
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Figure 22 Model VF100-ST vibratory filler counting machine (Model VF100-ST vibra-
tory filler, 2015.)
This is a very compact design and can be put on top of a table easily to
make the counting job faster. This can be a good integration with the pre-
sent working table. The price of this can be around 4000, 00 €.
7.2 Installing a moving product holder into the new working table
Currently, packers need to make packets manually and put it down to the
container. Then they pull products into the packet by hand as long as it
reaches to the exact amount. After that, they close the lid and finish mak-
ing the packet and repeat the same process again. If a counting machine is
added to the system, then after closing the lid and labelling, the packer
will have some spare time. So an automated moving product holder with
counting machine can be added to the system to make the process faster.
This will save some time too. The following idea is proposed for the new
hand packaging table. Figure 23 shows the new design of the working ta-
ble.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
29
Figure 23 New design of the working table with modified mechanism
The working table proposed above contains a precise counting machine, a
movable product holder and a converter for different types of packets. The
theory behind the table is, the counting machine will count a precise
number of products and then drop them into the movable product holder.
These holders have the volume as the largest packets size that will be
used. So, all types of products and amount will fit there. After filling one
holder, the mechanism will move forward clockwise and the next one will
be filled. At the end of the mechanism, there is a converter for different
sizes of packets. When those moveable holders will pass near the convert-
er and turn down, it will drop products into the converter due to gravity. A
packer will hold packets under the converter to catch the products into it.
Benefits of this mechanism:
Will save a lot of time as no setup is needed for different types of
packets
Machine will make the next counted products ready to fill in the
box
Products can be filled straight into boxes
Precise counting, no adjustment needed
Can count different shapes of products
In hand packaging section, generally a small batch of order comes, for
example, twenty boxes or fifty boxes. For this reason, product changes
frequently and also boxes. If a set-up time is needed for different boxes,
then the process will get slower. Most often, set up time is at least ten
minutes which is not worth for small batch. If this mechanism is applied,
that problem will be solved.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
30
Price information for this system: Except the counting machine, all the
other mechanisms need to make from the manufacturer with customized
settings. Because of this, the cost for this type of table will be a little bit
higher. One of the tables like this can cost around €6000-€12000. The cost
will be low if a standard mechanism is found in the market.
7.3 Using a counting scale with more capability of weighing
The present counting scale can count products having a maximum of
twelve-kilogram mass. Sometimes, there are some batches which have
more than twelve-kilogram mass. In this case, a packer needs to count the
products two times which is nothing but a time loss and slows down the
process. If this is replaced with another scale capable of counting up to fif-
teen kilograms of products, packers will save some time there which will
make the process much faster than now.
8 INVESTMENT RETURN
Investment return time is one of the core factors to consider when making
the decision to bring changes. The current semi-automatic machine is pret-
ty much old fashioned and needs to be changed one day. One of the im-
portant objectives for the thesis was finding solutions for low investment.
There are hundreds of different packing machines in the market and they
serve in different ways. While searching for those above mentioned solu-
tions, the following things were considered carefully:
What types of products to be repacked
Production rate
Batch size for production
Operation type in hand packaging and semi-automatic machine
Flexibility of the machines
Requirements of the company
Price of the machines
8.1 Manufacturing costs
Manufacturing cost is included two main parts which are fixed costs and
variable costs. If they are put in an equation:
TC = FC + VC (Q) (8.1)
Where, TC = Total cost
FC = Fixed annual cost (€/year)
VC = Variable cost (€/pc)
Q = Annual quantity produced (€/pc)
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
31
The figure 24 shows the breakeven point for a manual and automated pro-
cess for the same operation. This is a general presentation.
Figure 24 Fixed and variable cost as a function of production output for manual and au-
tomated production methods
From the figure 24, it is seen that if the production quantity is low, the
manual method is cost effective but as the production quantity increases,
the automated method becomes more efficient and cost effective. (Groover
2008, 73.)
8.2 Investment return calculation for semi-automatic repacking machine
Let’s assume that the company is interested in installing the above-
mentioned machines except the robot. For semi-automatic packaging im-
provement, the estimated cost is shown in table 3.
Table 3 Estimated cost to install new semi-automatic production line
No. Machines Cost
1 Counting machine 10000,00 €
2 Labelling machine 4000,00 €
3 Box maker 6000,00 €
4 Conveyors and other setup cost 15000,00 €
5 Total fixed cost 35000,00 €
So the total fixed cost is 35000,00 € for the whole setup. Variable cost is
taken as 0,01 € per packet. If 2500 pcs packet is being made in each work-
ing day, then annual production quantity is 2500*250= 625000 pcs packet
(considering two hundred fifty working days in a year)
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
32
So, total annual cost will be
TC = FC + VC (Q) = (35000+0, 01*625000) €
= 41250, 00 €
So for the first year, the total cost for the machine will be 41250, 00 €and
from next year only the variable cost (0, 01*625000) = 6250,00 € will be
added.
Now, if the machines are installed it will make one hundred eighty packets
per hour (considering the lowest efficiency) which is eighty packets more
per hour.
In an eight hour shift, 7 hours of work is done and 1 hour is break time. So
for two shifts (14*80) = 1120 more packets will be made.
For the presently installed system, it will take eleven hours of work to
make this much of packets. So the new system will save eleven hours of
work each day.
If a worker is given 10€/per hour as a salary, then (11*10)= 110 € will be
saved every day.
For 250 working days in a year, (250*110)= 27500,00 € will be saved
yearly.
So, in 2 years, (2*27500,00) = 54000,00 € will be saved.
In two years the total cost for the machine will be (41250, 00+6250, 00)=
47500,00 €
So the required time to get the investment back is less than 2 years (around
1.5 years).
A short version for the earlier calculation was shown in the figure 25. The
estimation includes only the cost of buying new machines and the installa-
tion cost. It excludes the price and installation of the robotic palletizing
system. Lowest efficiency was taken into consideration from the machines
which will definitely vary in real case but not that much. The estimated
investment return calculation for the new hand packaging table can also be
calculated using the above-mentioned way.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
33
Figure 25 Estimated investment returning time for both repacking processes
The case company was looking for a solution that will cost less than
€100000 so it seems that the proposed solutions met the objectives. Alt-
hough it is quite clear that the investment might vary while setting it up
but it will definitely not go close to that amount.
9 RESULTS
As different scopes of developing manual and semi-automatic packaging
processes are discussed above, a question comes how much efficiency will
be improved and how fast will be processed than now. An improvement in
efficiency based on calculation and assumption is discussed below.
9.1 Efficiency improvement for the semi-automatic repacking process
The simulation with the proposed improvement shows that with the new
system, it is able to make around 3-6 boxes/minute. Although the process
is completely dependent on product properties and quantities, even if the
lowest number is taken into consideration, three packets will be made in
each minute. This makes around one hundred eighty packets per minute.
In a full working shift of seven hours (deducting one hour break time),
around twelve hundred sixty packets will be made which is 80% more
than now. The highest number can go two thousand five hundred twenty
packets per shift which is 260% higher than now. So, even if it stays
somewhere in between, it is expected to have more than 100% increase in
production and around 75% increase in efficiency.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
34
9.2 Efficiency improvement for the manual repacking process
At present, hand repacking has a production rate of sixty packets per mi-
nute. With the proposed improvement, the packer will save some time for
counting and the production rate can reach up to hundred packets (as-
sumed value, comparing the process to the present semi-automatic packag-
ing section) per minute. This will produce around at least 67% increase in
production rate and around 33% increased efficiency for the process. The
percentage might vary in the real case, but this is for sure that the process
will be faster with the proposed improvements.
So the following objectives of the thesis were obtained:
Successfully found new precise counting machine
Market research was done to find right solutions
Complete process layout and packaging for faster packing were
proposed
Price for all the solutions was in the range that the case company
required
10 RECOMMENDATIONS
In addition to the earlier improvements, some other extra issues can be in-
troduced for improvement. These are discussed in the following.
10.1 Using flat boxes for longer products
All of the packets that the company is using now open from the short
edge. This creates a problem when filling up longer products which have a
length of more than one hundred mm. This slows down the process and
sometimes it takes twice as much time to pack the products. If the packet
can be opened from the long edge, it will make it much easier for the
packer to fill up the packet. In that case, half of the packaging time can be
saved. Each packer gets this kind of products at least once in a shift so the
time saving will depend on the batch size of the products. Figure 26 shows
the recommended changes of the box opening.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
35
Figure 26 Box that can be opened from long edge for longer products
10.2 Installing two computers close to the working area during summer
At the moment, there is only one computer located close to the working
area being used by the employees to input important data to the warehouse
management software. There are some other computers located in other
rooms close to the station. It was monitored that most of the time the em-
ployees were not interested in going there. This created a queue in front of
the computer during the summer, when several summer workers come to
work. On an average, a packer needed to go to the computer around five
times a day. Sometimes they needed to wait up to five minutes for their
turn depending on the queue. This way a packer lost twenty five minutes
of his working time in a shift. Around twenty people are working in the
packaging section during summer which makes a total loss of time five
hundred minutes in a shift. If only half of this loss is taken into considera-
tion; it is still a loss of more than four working hours. This problem could
be solved just by installing another computer right beside the present one.
This would create less gathering in front of the computer and will speed
the process up.
10.3 Repacking into small bags
Without manual repacking and machine repacking sections, the company
has another repacking called the ‘Small bags repacking’ section. In this
section, repacking is performed into small plastic bags. Counting is done
manually by the packer. As the counting process is done manually the
process is really slow. Sometimes more than one type of products needs to
be put into the same bag. In that case, the process is even slower than
normally. But there are several automatic machines in the market, which
could perform the counting job and mix different products automatically
along with filling them into plastic bags. In this case, the packer only
needs to put different products into different containers and tell the pro-
gram how to operate. The machine will do the rest by itself. This will save
a huge amount of time for the packer and make the process much faster
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
36
than now. The machine illustrated in figure 27 was chosen for considera-
tion.
Figure 27 Model ZB-60D4, 4-head counting machine for small bags filling (Zhongbai-
pack, 2014.)
Reasons behind choosing this counting machine included:
Precise counting
Able to put four different products into a single packet
Can count small screws, nuts, bolts and other parts of variable siz-
es
Capacity to fill 30-70 bags per minute depending on variable prop-
erties
Bag measurements: Length:20-145mm ,Width:50-170mm
Product counting, bag making, filling, sealing, and counting bags
is automatic
Easy to operate and reliable
Faster and smarter process than the present series counting job
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
37
The above-mentioned machine has four heads, but it is possible to custom-
ize the head numbers according to company needs. The case company can
order a machine with more or fewer heads based on their needs.
Price information for this machine: This kind of machines can cost around
€6500- €10000 depending on the number of heads and other properties.
11 CONCLUSION
This thesis work presented the possible solutions to the present problems
that are affecting the repacking processes. It helped the author to know the
working environment and the factors to be considered while working with
the company for real solutions. During the work, feedback from both the
supervisor and the company personnel helped the author find more realis-
tic solutions. One great and important lesson learned was that while work-
ing towards real solutions, some solutions might seem great at the begin-
ning but not that real and helpful in the end.
While designing a new mechanism for the box maker and a new working
table, the detailed working design was ignored here. It would be great to
make a simulation work for the process but due to the limitations of tutori-
al material for related software, this was also ignored. More design work
needs to be applied to all the solutions. The work aimed at showing a pos-
sible working method to design new processes for different tasks rather
than at providing detailed design.
Although there were some limitations to the project, the core objectives
were achieved nicely. The solutions found are expected to help the
company to increase their production in repacking. The new design of
packaging will benefit the process immediately. Other solutions will take
some time, but they will definitely help with the production rate. The case
company has sister companies to implement the recommended solutions.
Further checking might be needed before implementing all the solutions.
Once they are implemented, the production of the repacking sections will
be increased a lot and the purpose of this thesis work will be fulfilled.
Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
38
SOURCES
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Cup Fillers. Busch Machinery. http://busch-machinery.com/Cup-
Fillers.htm. Referenced 26.11.2015.
Direct industry. Articulated robot/6-axis/precision/palletizing UR10.
http://www.directindustry.com/prod/universal-robots-s/product-101499-
990381.html. Referenced 26.11.2015.
E-packing S.r.l. URANO SPT PRINTERS DESK.
http://www.epackagingsrl.com/prodotti_section/urano-spt-con-stampanti-
desk/. Referenced 26.11.2015.
Groover Mikell P. 2008. Automation, Production Systems, and Computer-
Integrated Manufacturing. United States of America: Pearson Education
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ID technology. Label Printer Applicator IDT model 252.
http://www.labelingsystems.com/products/label-printer-applicator/. Refer-
enced 26.11.2015.
Model VF200-HDX vibratory filler . All Fill. http://www.all-
fill.com/filling-machines/vibratory-fillers/model-vf200-hdx/. Referenced
26.11.2015.
Model VF100-BF vibratory filler . All Fill. http://www.all-fill.com/filling-
machines/vibratory-fillers/model-vf100-bf/. Referenced 26.11.2015.
Model VF100-ST vibratory filler. All Fill. http://www.all-fill.com/filling-
machines/vibratory-fillers/model-vf100-st/. Referenced 26.11.2015.
S-6 Cascading style Net weight Filling System . Busch Machinery.
http://busch-machinery.com/net-weight-fillers.htm. Referenced
26.11.2015.
Zhongbaipack. Automatic packing machine with 4 counting systems.
http://www.zhongbaipack.com/product/html/?39.html. Referenced
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Cost optimal development of processes for manual and semi-automatic packaging sys-
tems
Appendix 1
CONTACT DETAILS OF RELATED COMPANIES
ALL-FILL Inc. 418 Creamery Way
Exton, PA 19341
p 1·800·334·1529
f 610·524·7346 (All - Fill)
f 610·363·2821 (Auger)
Busch Machinery, Inc.
727 E. 20th St.
Tucson, AZ 85719
Website: http://busch-machinery.com/
Phone: 800-840-9573
Fax: 800-840-6270
(USA Only)
Phone 520-777-3360
Fax: 520-777-3369
Epackagingsrl
Via Gabriele D'Annunzio, 5, 20835 Muggiò MB, Italy
Website: http://www.epackagingsrl.com/
Tel +39 039 2781718
Fax +39 039 2781722
Guangzhou Zhongbai Packaging Equipment Co., Ltd
Address: NO.123 Junhe Street, Xinshi Road, Guangzhou City, China.
Tel: (020)22100302
Contacts: Ms.Crystal Zhou
E-mail: [email protected]
Mob: (0086) 13168896302
Skype: crystal.zhou86
http://www.directindustry.com/
Labelling Systems 48 Spruce Street
Oakland, New Jersey, 07436
Web: www.labelingsystems.com
Email: [email protected]
Phone: 201-405-0767
Fax: 201-405-1179