“One Team – No Borders”
Krones Starmatic Labeler
Salad Dressing Line
Downtime Reduction
“One Team – No Borders” IntroductionCharter• Problem Statement - During the first 8 periods of 2011 the Starmatic
Labeler saw 10,285 minutes of downtime and accounted for 30.7% of the total unplanned equipment downtime for the Liquid Salad Dressing Line. The reliability of this piece of equipment was responsible for stopping the filler operation 2,842 times, thus interrupting the production process. At an average rate of 160 bottles per minute, this downtime accounts for lost production of 205,702 bottles per period.
• Project Objective – Decrease the Starmatic Labeler unplanned downtime by at least 50% or 643 minutes per period by March 1, 2012. This will be accomplished by optimizing the Maintenance Excellence process to ensure greater reliability and consistency across all three shifts. This project will deliver an estimated annual cost savings of $58,008 and set a Maintenance Excellence standard that can be applied across the plant.
“One Team – No Borders” Team
“One Team – No Borders”Identifying areas for
Improvement
FMEA
Process Map
Fishbone
“One Team – No Borders” Focus Areas
• Preventative Maintenance• Cleaning and Inspection• Training / Troubleshooting• Equipment Repairs• Changeover• Material - Labels
“One Team – No Borders”
PREVENTATIVE MAINTENANCE
Want to move from Reactive to Proactive Operations
“One Team – No Borders” LubricationProviding a detailed PM procedure for greasing the equipment
Daily Gripper cylinder: 1 drop
per cam roller station (4) after each caustic
Lubricate pallet turret, one drop per: bushings (5 front; 6 back) on pallets
Lubricate the glue roller upper/lower bearing
“One Team – No Borders” LubricationWeekly Lubricate remote grease
fittings and check the reservoir for the bottle plate
Lubricate the pusher-plate guide rod on the label baskets so the pusher plate travels smoothly and freely
Oil the rollers on the cam followers
Lubricate the three gearwheels underneath the panel with a light coating of grease
“One Team – No Borders” Inspection
Frequency of Inspection Monthly vs Quarterly
Procedures Better detailed equipment checks
Change Over Parts Inspecting parts
Planned Job Package Repetitive File 50,000 in EMPAC Retiming equipment
“One Team – No Borders” InspectionWeekly Visual Inspection
“One Team – No Borders” Inventory
ObsoleteSurplusLocation
Standardization
“One Team – No Borders” Cleaning as Inspection
Before After
“One Team – No Borders” Cleaning Procedures
“One Team – No Borders”Daily Operator Inspection
• Operator Ownership
• Ensures Daily Inspection Are Completed
• Identifies Maintenance Issues
“One Team – No Borders”Operator Training
• Krones Training• Developing Customized Training Manual
– Knowledge Assessments• Troubleshooting Guide
“One Team – No Borders” Maintenance Training
Part of the charter was to improve the efficiency of our mechanics on
identifying breakdowns and the ability to correct issues quickly with consistency. This will help eliminate extended down time
events and create common adjustment points.
“One Team – No Borders” Maintenance Training
Training Program 66 Schedule Krones to Conduct General Equipment training for Operators
and Mechanics
67 Schedule Operators and Mechanics to attend Training (provide necessary coverage)
68 Document Standardized Work Procedures and SOPs for running equipment
69 Develop operator training plan with certification requirements for future operators and mechanics
70 Create Troubleshooting Gide 71 Develop daily operator checklist
Developed an action register to determine opportunities for Maintenance Training
“One Team – No Borders” Maintenance Training
• Krones Training:– Doug Paswatters– January 3rd thru 6th of 2012
Presented Cold-Glue Rotary Training for Line Technicians and Maintenance
“One Team – No Borders” Changeovers
• Reviewed the current change over procedures and updated them to a step by step system to achieve more consistent results. With this new format we are looking to have repeatable change overs that deliver consistency, quality and reduced time on vertical start up’s.
“One Team – No Borders” Changeovers
91 Make a detailed list of all adjustments and settings that can be made to the labeler
92 Verify set points for each adjustment and each package size93 Document changeover procedures with SOPs94 Conduct changeover training with Operators and Mechanics95 Mark all gages and scales with min/max settings96 Review current changover procedure97 Develop Changeover Checklist for Maintenance and Operations
Change Over Action Register
“One Team – No Borders” Changeovers
“One Team – No Borders” ChangeoversStarmatic Labeler Changeover Sequence
[ ] Back Side of Labeler Remove: Infeed Guide (adjustment) Remove: Discharge guide (adjustment)1 [ ] Remove: Discharge starwheel2 [ ] Remove: Centerguide3 [ ] Remove: Infeed starwheel4 [ ] Remove: Feedscrew5 [ ] Install: Feedscrew, and adjust to package" Remove: Bottle gate (adjustment)6 [ ] Install: Infeed starwheel Install: Infeed guide - (adjust)7 [ ] Install: Centerguide8 [ ] Install: Discharge starwheel9 [ ] Install: "Discharge guide, as required"
Front Aggregate
10 [ ] Remove: Front Label basket *The Operator should have this done before the Mechanics are finished with the Back Side of the Labeler. (Do not lift using pusher-plate rails)
11 [ ] Remove: Front Label pallets *The Operator should have this done before the Mechanics are finished with the Back Side of the Labeler.
12 [ ] Install: Label basket (do not lift using pusher-plate rails.)13 [ ] Remove: Front Gripper cylinder14 [ ] Install: Front Gripper cylinder15 [ ] Install: Front Label pallets
Back Aggregate
16 [ ] Remove: Back Label basket *The Operator should have this done before the Mechanics are finished with the Back Side of the Labeler. (Do not lift using pusher-plate rails)
17 [ ] Remove: Back Label pallets *The Operator should have this done before the Mechanics are finished with the Back Side of the Labeler.
“One Team – No Borders” Equipment Repairs
“One Team – No Borders” Equipment Repairs
Lack of proper cleaning and PM’s lead to a labeler that was unreliable, unpredictable and in need of immediate attention.
“One Team – No Borders” Equipment Repairs
• Team identified repair opportunities and formed action register.
Train oilers and supervisors on new lubrication scheduleRun water lineCam Rollers are Worn and need to be replacedReplace all sight glasses on labelerReplace all oil reservoirs on lablerReplace all gages on labelerReplace rubber seals on all of the doors
Clean / Replace all door frames
Infeed star - center hub is cracked, make sure we have a spareSmall lexan panel by the back label did not get replaced during cleaning - replace small lexan panelCheck drive belt tension so that it can be added to the PMUpdate PMs with information from cleaning day, past history and FMEAInstall quick release handles for removing brushes for cleaningResearch and develop plan for replacing/ rebuilding main gear boxInsvestigate scheduing PMs on hours vs. days
“One Team – No Borders” Equipment Repairs
• As part of the action register and PM review we replaced over 60 different worn parts
“One Team – No Borders” Equipment Repairs
• Some parts that were replacedOut with the old In with the new
“One Team – No Borders” Future Work
We will change the culture to create a
cleaner, well maintained and efficient running
Labeler
“One Team – No Borders” Future WorkImproved Lubrication Program
“One Team – No Borders” Future WorkNew established cleaning procedures
“One Team – No Borders” Future Work
Improved PM Procedures
“One Team – No Borders” Future Work
Through Training and Team Work
“One Team – No Borders” Label Check Sheet
Kroger State Ave - Labeler Check Sheet Operator:____________________________Date:_______________________________
Time Product Name Front Label Back Label Neck Band Cap Type
Align Adhes Resource# Align Adhes Resource# Align Adhes Resource# Blue Red
1 Pre-Op2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
The first check is now considered the pre-op check. Once the labels are applied and in specifications and code dater blue and red have been set and the correct caps are in useperform the first quality check, While performing this check the line must be down when the containers meet the specifications then continue running production. It is important when checking the code dates to make sure both code daters are set correctly and are printing in the correct location on the container.
Every half hour and each changeover, check 3 containers for label alignment and proper adhesion of each label. If each label is acceptable, write "YES" in the blank provided. If not, write "NO" and note what was done to correct it in the comments section. Check the cap type against the pack specs. (Color/lined vs. unlined, etc) IF THE RESORCE NUMBER SPEC AND THE RESOURCE NUMBER USED DO NOT MATCHOR LABELS CANNOT BE APPLIED PROPERLY, SHUT THE LINE DOWN AND CONTACT A SUPERVISOR. Alignment should be no more than 1/4 inch skewed.
___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Revised 2/09/12 JB
Date Coder
• Operator Accountability
• Operator Awareness
• Eliminates Failure of Process Improvement
“One Team – No Borders” LabelsSpring Dot was here on January 24 and brought in their operators and upper management as well as one of their owners for this meeting. We used samples during the meeting as examples of improper cuts.
Spring Dot response:
We can just make the switch as soon as you can purchase the correct paper and obsolete the old inventory.
“One Team – No Borders” Downtime Tracking
“One Team – No Borders” Control Plan
Sustained Improvement Requires….• Involvement and Attention from Everyone!
– Operators, Mechanics, Production and Maintenance Supervisors, Superintendent, Maintenance Manager, Maintenance Engineer, QA, Kaizen Team, HR….
** Control Plan will be reviewed with all necessary parties for approval and signatures
“One Team – No Borders” Results
Minutes of Starmatic Labeler Downtime by Period
“One Team – No Borders”Minutes of Downtime Per Shift
(12/8/11 - Present)
12/8/2011
12/13/2011
12/16/2011
12/21/2011
1/6/2012
1/11/2012
1/17/2012
1/20/2
012
1/23/2
012
1/26/2012
1/29/2012
2/1/2012
2/4/2012
2/7/2012
2/10/2
012
2/13/2
012
2/16/2012
0.0
20.0
40.0
60.0
80.0
100.0
120.0
1st Shift Minutes Down
12/8/2011
12/13/2011
12/16/2011
12/21/2011
1/6/2012
1/11/2
012
1/17/2
012
1/21/2012
1/24/2012
1/27/2
012
1/30/2
012
2/2/2012
2/6/2012
2/9/2012
2/12/2012
2/15/2012
0.0
20.0
40.0
60.0
80.0
100.0
120.0
2nd Shift Minutes Down
12/8/2011
12/13/2011
12/16/2011
12/21/2011
1/10/2
012
1/13/2
012
1/20/2
012
1/23/2
012
1/26/2
012
1/29/2
012
2/1/2012
2/4/2012
2/8/2012
2/11/2
012
2/14/2
012
2/17/2
0120
20
40
60
80
100
120
3rd Shift Minutes Down
Minutes Down Per Shift Baseline (1/30/11 – 12/6/11) Trend
“One Team – No Borders” Downtime Trend
Reduced Variation
“One Team – No Borders” ResultsBaseline
#1 Downtime Event = Labeler30.7% of Downtime caused by Labeler After Improvements
#1 Downtime Event = Changeover24.2% of Downtime caused by Changeover
17.8% of Downtime caused by Labeler
“One Team – No Borders” Improvement and Savings
Avg. DT Min /Shift
Baseline (1/30/11 – 12/6/11)
After Improvements (12/7/11 - Present)
50% Reduction Goal
% Improvement
1st 10.4 10.8 10.0 ------
2nd 29.5 15.8 10.0 46%
3rd 20.2 15.2 10.0 25%
Total 60.1 41.8 30.0 30%
** In the 7 shifts since the maintenance/rebuild on 2/18-2/19 we have averaged 3.98 minutes of downtime per shift! That’s an 80% improvement from the baseline average.
“One Team – No Borders” Projected Savings
Actual Savings
12 13 1 2 3 4 5 6 7 8 9 10 11$0.00
$20,000.00
$40,000.00
$60,000.00
$80,000.00
$100,000.00
Project Savings - Calculated from Unplanned Downtime % Improvement** Savings calculated from average period downtime reduction only
30% Projected Improvement 50% Projected Improvement 75% Projected Improvement 90% Projected Improvement
“One Team – No Borders” What’s Next?30% Improvement = Current State
50% Improvement = Expectation after 2/18-2/19 Weekend Repairs
75% Improvement = Projected improvement after completion of the following: • Customized Operator Training Manual, Troubleshooting and Training• Improved Springdot Label Quality• Neck Band Labels with Horizontal Grain (3/17)• Downtime Code Standardization
90 % Improvement = Recommendations for future Teams/Kaizen Events• Rapid Changeover Event • Customized Maintenance Training Manual and Training Program• Cleaning Cabinet
** Control Plan Must Be Followed to Sustain Improvements
“One Team – No Borders”
Questions?