Packaging Operations, Singapore, IPT West Tablet Facility

Transforming the Nasonex Packaging line into a High-Speed, High-Output Operation

PACKAGING OPPERATIONS, SINGAPORE, IPT WEST TABLET FACILITY

• Replace the current Intermittent Cartoner with a Modern Continuous high speed Cartoner

• Adapt the F-350 Crimping Machine so we can run the USA product (Small Bottle).

• Evaluate Which Machines have the most trouble and why.

• Identify trouble points in the line and correct the Problems.

• Inventory and increase the Parts we keep in Stock.

• Inventory, increase & Secure the Parts we keep at the Nasonex line.

• Inventory Tools and ensure the Technicians have all the right tools to support continuous line operations.

• Procure Specialty Tools i.e.: Snake Camera, High Speed Camera, Bearing Extraction & Installation Kit, Drummel Diamond High Speed File, Special Drills & Bits.

• Purchase & make accessible all Hardware needed for the Line, Nuts & Bolts, Washers, Spacers, Clips, and so on.

• Re-write PM’s so they are effective and eliminate down time.

• Develop and implement a Maintenance check list to be Preformed between Batches.

PRIORITIES FIRST

CP-18 CASE PACKING MICHINE &

* We have changed the PM

plan to include a TPM

program.

* Created Job-Aids for

smooth & efficient product

change-over.

* Intensive training for

Trouble-shooting &

maintaining this machine.

MS-300 STRECH-BANDING MACHINE

MS-300 STRATCH-BANDING MACHINE

We ‘ve taken advantage of

a long overdue Up-grade

for the sealing unit on our

Stretch Bender. This along

with a improved PM Plan &

TPM replacement program

will allow us to run the

equipment at full

capacity .

OUR PREVIOUS CARTONERThe IMA Flexa Intermittent Cartoner

Uhlmann C 2205 CartonatorOur New Cartoner

Up until now it has always been

very difficult to Adjust the Star-

wheel Inlet & Outlet of this

machine, do to the fact that the

center Plate was one solid Piece!

That all changed in April 2013

when Engineering Tech “Siva

Kumar” devised a way to easily

make this adjustment.

“IMA” MS-300 LABELLING MACHINE

F-572 PLUGGING &CAPING MACHINE

Their were a few problems with

this machine switching/running

different products, however

nothing we couldn’t solve with a

few innovative ideas!

We enhanced the way the dust

cap is delivered to the Star-wheel

and made the process visible to

aid adjustment.

Finally, we enhanced the Star-

wheel to better fit all our

Products.

IMPROVING THE DISPENSING UNIT

Made More Reliable & Less Costly to Operate!

O.Z.A.F UNSCRAMBLING UNITS

O.Z.A.F

AC-1500

UNSCRAMBLER FEEDING SYSTEM

Before 100kg After 55kg

Lighten the load

One of Eight selection disks One of two center pieces

Maintaining Balance

Panasonic motor & gear box The OZAF AC-1500 Feeder

Too much of a job for a little drive unit

Reduced weight = Reduced STRESS

Due to the excessive weight of the 1 inch thick solid Metal mounting Plate and the 2.5 inch thick solid Teflon surface of our two Unscramblers, we were seeing (on average two times per year per Unit) unreasonable brake-downs from broken motor shafts, burned out motors, and bad gearboxes. The lost time from any of these conditions is 4-6 hours and often exceeded eight (8) hours or more if parts were not available.

The Pervious Photos show how we corrected this problem, without changing in any way the functionality of the Machine!

They say a Picture is worth a thousand words………..

RAMSEY 9000 HIGHSPEED CHECKWEIGHING SYS ‘Primary Side’

This Unit historically has

been a major source of

production slow-downs &

line stoppage’s since start-

up, mainly due to the Input

Scroll feeding system &

the Output system!

RAMSEY 9000 INFEED SCROLL SYSTEM

What you see here is the old

In-feed Scroll system for the

Ramsey 9000 Check

weighing Unit. Basically the

theory of operation is good.

The main trouble is the

original scroll! It is not a

proper fit for our product, so

the system often crashes & is

difficult to adjust.

A PLC Driven Star wheel Feeder! “Suggested by local contractor” $35,000 SG

My modification of the existing Scroll feeder features, double ball bearings on each side of the Scroll & a chain drive system…. No more broken Belts…! Costs: $2,100 SG

KEEPING IT SIMPLE

RAMSEY 9000 OUTFEED SYSTEM

Keeping it Simple

EASY OUTKEEPING IT SIMPLE

My design is

simple, no

wearable moving

Parts, no

Maintenance cost!

Cost: $800 SG

Our Old System The New System

HIT OR MISS

From Start To Finish

ON TARGET

Speedy Replacement Simplicity

REPLACING PARTS MADE FAST & SIMPLE

SUMMERY CONCLUSION

With a few simple ingenious design changes/modifications, I was able to prepare the Thermo Ramsey 9000 plus High-speed check weighing system to perform at the higher production levels which will be required to support our new Uhlmann C 2205 Cartonator.

Modifying the in feed scroll feeder: $2,100 SG

Modifying the out feed cross over: $800 SG

Enhancing the “Thermo Ramsey Primary Check weighing system” for under $3,000 SG, instead of $55 to 60,000… PRICELESS…..!

EFFICENT CRIMPING

Fast, Stable, Reliable!

F-350 ROTARY CLOSING MACHINE

Numerous Improvements

have been made on this

Machine. Starting with the

Crimping-heads, the Short

hose sensor, Missing hose

sensor, SVIM Camera

system, the Pump Gripper

& the Pump Dispensing-

head!

THE PUMP DISPENSING HEADAdjusting this unit to run smoothly,

without stoppages & break downs has

proven very difficult for the operations

personnel.

1. You cannot see the Pump as its

being dispensed.

2. The Dispensing arm continuously

seizes up during operations.

3. The Pump gripping arm occasionally

crashes into the Dispensing Unit,

causing enormous Damage

resulting in lengthy down time.

The original Pump Dispenser Our Improved Pump Dispenser

TO SEE OR NOT TO SEE….?

IMPROVED PUMP DISPENSING UNIT

1. Most noticeably you can now see the

Pump being dispensed.

2. Two ball bearings have been added

to the dispensing arm shaft so as to

facilitate smooth continuous

movement without seizing up.

3. The front of the Unit has been

designed to “Break Away” in the event

of a crash! It has been cut away and

reattached using Nylon or Aluminum

screws.

Old E3X Omron Analog Fiber optic sensor New 3rd Generation E3X Advanced Digital sensor

UPGRADING TO THE 21st CENTURY

Short Suction hose Sensor: Before

Short Suction hose Sensor: After

EASILY ADJUSTABLE SENSORS

Before After

PUMP GRIPPING CAROUSEL

Temporary Prototype Permanent Units

F-350 Crimping Station

This is the proof of Crimp sensor,

it has also been given a new

Easy Adjustable stand….

CRIMPING

EASY ACCESS & EFFICIENT MAINTENANCE

Access Ports have

been Installed to

allow quick access

for cleaning the

vacuum lines and

maintenance.

PUMP/BOTTLE DESPENSING BLOCK

If you look closely you can see the new V-Cone shape which was added to the Pump Carousel which guides curled stems smoothly into the bottle!

Also 3mm has been shaved off the bottom of the Block to prevent it from hitting the crimping star-wheel. This has stopped the unnecessary shaking, so we now run smoothly…

Our Current Star-Wheel New High Performance Model

SELF CLEANING STAR-WHEEL

Hold-Down Shields Close-up

ON TARGET EVERYTIME

PUMP/BOTTLE DESPENSING BLOCK

Old Block……

New Block: Note the V-Shape Pump stem insertion tunnel “This prevents Pump drop-off due to Curled Pump stems”, and an added 2mm for bottle height adjustment gives us more flexibility to set-up the Pump Carousel

sol.

IMPROVED CRASH SAFETY DEVICE

This Device has been modified to prevent crashes into both the Crimping Head and the Pump Dispenser! It also locks in the tripped position, forcing the operator to inspect before re-start!

Safety Device trigger is set at 1mm in height…..

A NEW PUMP GRIPPER ARM

New Design firmly grips the Pump and totally prevents Drop-offs……

Note the lip on the upper Pump gripper! “Drop-offs are responsible for over half our rejects……..”

Through Beam Technology Every Piece Counted

SHORT HOSE SENSOR

MAKING ROOM FOR A BETTER MEASUREMENT

Comparison Comparison

IMPROVED PUMP GRIPPING TIMING

SUPERB GRIPPING EVERY TIME

Easy to see why pumps dropped off so often, causing crashes and unnecessary downtime for repairs…

Notice how the Pump is setting perfectly in its seat and held firmly, ready to be transferred to the Crimping Head…..

Adapting the Crimping Head

to Accommodate all Nasonex

Components'!

With absolutely no changes to the

way the crimp-head functions, it

has been adapted to allow us to

crimp all our Nasonex components

using one style of Crimp-head

NASONEX CRIMPING DEVICE

Seven major components:

* Piston

* Suction nipple

* Capping mold

* Spring

* Spring seat

* Crimping fingers

* Closing ring

Only the Suction nipple, Capping mold and

the Spring were adapted to achieve our

goal

CRIMP-HEAD MAIN COMPONENTS

COMPLETE CRIMPING

The end result of all

these modifications

“A perfect Crimp, on

any size bottle,

using any Pump”

with only one

Crimp-head…….!

F-540 ROTARY FILLING MACHINE

The PM Plan for this Unit has been

revised to include the following!

• Replace wearable Parts on all

Valves, Syringes, Valve guides

every 6 months.

• Replace all Bearings Yearly & a

inspection PM conducted Bi-

Yearly

• Replace in feed & out feed

conveyor Belts every 4 months.

EFFICEANT PM & REPAIRThis Station is equipped

with an abundance of all the

wearable parts associated

with the F-340 & F350 filling

and Crimping machines!

All the proper tools,

Instructions, technical

references & job aids are

visible and located for easy

access…..!

This Ingenious little Machine is the

work of one of our Engineering

Technicians “Siva Kumar”…….

This Machine will give us the ability

to pre-set the off duty Crimp-heads

to a perfect Crimp setting, on the

bench! It will expedite the change

over & start-up time and will allow

us to be in a constant state of

readiness with Crimping……

CRIMPING PRE-SET STATION

FINAL SUMMERY• Every PM Plan has been upgraded to enhance the performance &

reliability of the Equipment!

• Error code & Troubleshooting guides, along with a General description & Technical data, Settings & Adjustment Instructions, Format change-over Instructions are positioned at every machine where they are highly visible & ready for use….!

• Detailed Job Aids along with “How too” Photos have been made and are placed at the machine “Highly Visible”……!

• A detailed check-list of “Must Due Maintenance” has been developed, and will be performed in-between batches to keep the line at the highest operating condition at all times.

• A computer is now out on the line, containing a complete set of all Technical manuals for all machines on the line.

• Every Machine has been evaluated for trouble areas and corrected, all difficult adjustments have been made easy & accessible.

• We have tripled the amount of Parts we keep in Stores and down on the line! Plus all Parts on the line have been categorized, Inventoried, and Secured under lock & key.

• We are in progress of replacing all of the PENTA 5XSA DC motors along the entire line conveyor system.

• All conveyor belts and their associated bearings have been replaced.

• The Fiber Optic sensors & Optical sensors on the F-350 and F372 Closing & Capping machines have been upgraded and replaced.

• A special “work station” is now available to rebuild the Crimping heads, Filling valves & associated parts.

• We have developed a “OFF LINE” Crimping station, equipped with special tools for setting & adjusting the Crimp heads to a perfect crimping position 3.85mm.

• We now have two complete sets of Crimping heads that will be rotated in & out of service every 2 weeks or as required. This will allow for expedited maintenance turn around!

• The Ramsey 9000 CHK Weigher for the Primary side has under gone a major upgrade and is now ready to deliver a much higher output!

• Special tools & equipment have been Invented to perform special tasks & put to use to enhance troubleshooting and expedite unscheduled maintenance.

•

WHERE WE BELONG