TOP 3 WAYS
TO OPTIMIZE YOUR PRODUCTION SYSTEMS
Almost all manufacturing shares
fundamental truths and suffers similar pitfalls.
start-up
& commissioning
AUTOMATION
& CONTROL SYSTeMS
MODELING & SIMULATION
1
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2
3
Here are the top three ways to optimize your production systems:
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This guide explains the importance of formulating a plan to optimize your production systems. Haskell's automation team provides expertise to utilities, food and beverage manufacturers, process plants and more. With more than 50 years of experience, Haskell professionals can provide insightful analysis, planning, design, construction and integration in all phases of manufacturing projects big and small.
WE HAVE CREATED A GUIDE TO HELP OVERCOME YOUR PRODUCTION CHALLENGES
USA | MEXICO | COLOMBIA | ECUADOR | CHINA
MALAYSIA | PHILIPPINES | SINGAPORE | VIETNAM
Haskell has assembled a guide to address these common challenges and help ensure your production facility operates at the speed needed to meet customer demands.
Delays in startup means demand goes unmet.
Labor is expensive and difficult to find.
Productivity of existing lines degrades.
Automation for Process & Packaging
ANALYZE YOUR CURRENT WORKFLOWS & EXISTING FACILITIES
START-UP
& COMMISSIONING
1
2
3
Here are three ways to optimize production systems, according to Haskell's Subject Matter Experts:
Sub-optimal production lines
can pose substantial risks
to your bottom line, including: diminished product quality, delayed outputs, and equipment deterioration.
TOP 3 WAYS
OPTIMIZE
YOUR PRODUCTION
SYSTEMS
Automation for Process & Packaging
1
ANALYZE YOUR CURRENT WORKFLOWS & EXISTING FACILITIES
2
START-UP
& COMMISSIONING
3
Automation for Process & Packaging
1
One of the biggest issues these days
is related to manpower labor. After
the pandemic, manufacturing plants eliminated or suspended a lot of jobs managed by people, and then when they wanted the people back, they suffered
to find qualified employees, automation
for process & packaging has become a
great solution to this labor shortage.
How does automation for
processing & packaging work?
Packaging requires a wide array of machinery and systems, usually made by different original equipment manufacturers (OEMs), to produce goods successfully and efficiently.
Most OEMs supply only their piece of
the puzzle, so engaging a partner to implement reliable packaging and material handling automation solutions is critical to making your line function seamlessly.
Incorporating additional layers of communication ensures that OEM (original equipment manufacturers) equipment is fully integrated, improves overall line balance and maximizes critical data interface to reporting systems. Additionally, it is crucial that you understand your controls platform to design and integrate a system that is familiar to the maintenance team, reduces spare-part costs and improve overall performance.
Enforce client or provider controls standards with each OEM to develop a common controls platform.
Use real-world values, such as product size, conveyor width and maximum conveyor speed, to control the system.
Incorporate product recipes that make the system flexible and allow personnel without a controls background to securely maintain existing products or add products.
Keep programmable logic controller (PLC) logic simple and easy to follow.
Present operators with the information they need on the human-machine interface (HMI) to understand their status and avoid nuisance warnings and alarms that become a distraction.
The team of packaging experts should achieve these marks, whether with a new or existing line, by following a simple strategy.
All these practices result in an automation system that is reliable, flexible, and easy to operate, and does not require a full-time engineering service to support.
CASE STUDY:
Controlling an Out of Control System
A client came to us with a familiar problem: Their bottling line was fraught with multiple efficiency and quality problems. The line, which included a new packer and sealer with associated empty-carton, full-carton and full-bottle conveyor systems, produced numerous issues that the original integrator was unable to resolve:
Haskell’s packaging automation team investigated each of the issues, and within two days, turned over a system that was balanced and jam-free. The following is a summary of the steps taken for each problem area.
Full-bottle breakage because of excessive line pressure
Inadequate empty-case supply resulting in frequent packer micro-stops
Empty-case system jams at curves
Jams at the discharge of the case sealer
The Haskell team employed our core conveyor control strategy and recalculated the conveyor speeds based on the bottle sizes and conveyor width to derive desired speeds in bottles per minute. Once this was complete, the packer and bottle conveyor speeds were modified to follow each other based on the status of the packer infeed sensors (Low, Medium and High).
Due to long, non-accumulating sections of conveyor prior to the packer, the empty-case system was not supplying a steady flow of empty cases to the packer, resulting in frequent low-prime situations. To resolve the issue, the original turnkey supplier added an accumulation mode to help close gaps, but this action instead increased case pressure at the curves and created case jams. As a result, the accumulation mode was disabled, leaving the system unable to adequately supply empty cases to the packer.
Empty Case Supply and Jams
Bottle Breakage
When downstream issues caused the case sealer to stop, cases would jam at the sealer discharge. After investigating, the team determined that there was not enough physical space to properly run out the sealer. Stopping the sealer in place was not an option, because doing so would result in cases not sealing properly and frequent stops due to open flaps.
Sealer Jams
By employing the basics of relating product sizes to conveyor speeds, Haskell can improve a system that isn’t operating as expected. This method can also be used to optimize systems that are layout constrained. Following these methods takes the guesswork out of line control and results in a system that runs reliably with minimal product loss or damage.
Summary
With a proper bottle-per-minute relationship established between the packer and the bottle conveyor, bottle pressure was eliminated, and the packer was able to maintain steady-state operation rather than varying speeds and occasionally stopping because of to low bottle prime.
To solve the issue, Haskell’s team once again relied on the basics. We recalculated the conveyor speeds based on the length of the case and the desired speed of the packer. Once the conveyor speeds were established, the conveyor logic was modified to follow the speed of the packer rather than relying on the preset speeds previously used.
To manage the issue of gaps, the conveyor logic was modified to accumulate further upstream and properly meter cases through the curve instead of trying to accumulate through the curve. When larger-than-expected gaps were detected on non-accumulating conveyors, the conveyor speeds would modulate to close the gap. By the time the cases were on the last non-accumulating conveyor, a large decline belt, there was a consistent flow of cases heading to the packer, which eliminated the frequent low prime issue.
To resolve the issue, the team recalculated the conveyor speeds based on the length of the case and the desired bottles-per-minute speed of the sealer. Once this relationship was in place, the team calculated and implemented the space and conveyor speeds necessary to create the physical space required to run out the sealer.
problem area:
problem area:
problem area:
◆ Conceptual Planning and Analysis
◆ OEM Equipment Selection
◆ Control System Estimating
◆ Coordination with In-House Mechanical and System Analytics Teams
◆ System Design
◆ Legacy System Migration
◆ Standards Development
◆ Software Development- PLX, HMI Software Development- MES Systems- Historian
◆ Project Management
◆ Simulation and Emulation
◆ Installation/Construction Support
◆ Safety Design and Verification
◆ System Commissioning
At Haskell we offer the following capabilities & experience to help your company to automate processes & packaging:
TOP 3 WAYS
YOUR
PRODUCTION
SYSTEMS
TO
PTIMIZE
TOP 3 WAYS
YOUR
PRODUCTION
SYSTEMS
TO
PTIMIZE
