White Paper 6 Golden Rules to Increase the Efficiency...6 Golden Rules to Increase the Efficiency White Paper and Service Life of Your Checkweigher Contents 1. First-hand knowledge

6 Golden Rules to Increase the Efficiency and Service Life of Your Checkweigher

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Contents

1. First-hand knowledge based on experience

2. 6 Golden Rules – Based on practical experience, not plucked from thin air

2.1 A good start. Proper commissioning

2.2 Well prepared. Optimum training

2.3 Well maintained. It is the small things which make all the difference

2.4 Well observed. Seeing and acting go hand in hand

2.5 Well maintained. On the safe side – thanks to expertise

2.6 Well situated. Precise weighing requires defined site conditions

3. More detailed information

No portion of this publication may be reproduced or transmitted for any purpose without the express written consent of Mettler-Toledo Garvens GmbH regardless of what type and manner or by which means this occurs.

All rights reserved. Subject to technical changes.

Mettler-Toledo Garvens GmbH offers no guarantee for the accuracy or applicability of the included information and is therefore expressly not responsible for damage to property and/or for personal injuries that result directly or indirectly from the use of this information.

16 Golden Rules to Increase the Efficiency and Service Life of Your CheckweigherI

METTLER TOLEDO Garvens White Paper – www.mt.com/garvens-gold

1. First-hand knowledge based on experience"Even a tiny hole can sink a large ship." Observation and experience have always manifested themselves in small nuggets of wisdom, such as the above quote. The often form part of our general vocabulary. Their core truths grab your attention, make you smile and make good sound common sense. Who cannot relate to the experience of the noted triviality becoming a major problem? Unfortunately this happens more often than expected. In retrospect, those affected often note that prevention of the development would have been very simple. Practically child's play. Somehow no-one paid enough attention. Even though it would not have taken much effort…

Lessons from daily life are reflected in everyday company life. Inattention mixed with a measure of mis-placed trust often causes efficiency to suffer. High-precision machines and instruments often have shorter life spans or require additional maintenance and repair because employees do not heed service instructions or have overlooked warning indications. Little acts of inattention can, under certain circumstances lead to disaster. Machines may need to be replaced sooner or cause more stoppages because of required repair or maintenance work. The comparison with a new car comes directly to mind: Those who perform the prescribed vehicle inspections on a regular basis, continuously care for it and quickly notice changes such as unusual noises, etc., will drive well, safely and more economically in the long run than those who only think about keeping the tank full.

Dynamic checkweighers are high-precision "workhorses" which are designed and built for their particular purpose. They are in general designed to be robust and sturdy to meet today's production requirements. Nevertheless, they are not invulnerable. The diverse experiences of service engineers and supervisors in manufacturing have shown that responsible handling of these precision instruments increases the lifespan and ensures consistent output. If employees who work with checkweighers follow a few instructions, they can make a significant contribution towards maximising the efficiency and profitability of the production line for the benefit of the company.

So, just as the friendly car dealer always reminds the driver about his inspection intervals, it makes sense to make increasingly clear to one's own employees that care, maintenance and a keen eye ensure maximum operational availability. The following 6 Golden Rules in this White Paper form the essence of many years of practical experience – key points from the world of business.

2. Six Golden Rules: Based on practical experience, not plucked from thin air

Technological progress in checkweighing technology has made it possible to substantially simplify the operation, sharply reduce the measuring time of each weighing process and to make checkweighers so adaptable that they can now directly control many production processes. They are precision multi-function devices and, when observed in continuous daily production, appear to be indestructible. Nevertheless, precision checkweighers require a certain degree of attention in order to ensure seamless processes and full functionality.

Careful and machine-compatible handling of a dynamic checkweigher begins at hour zero, proper commissioning on-site at the customer's location. Employee expertise is built up via provision of information, instructions and training. Regular care and maintenance, whether autonomously or via external technical personnel, ensures that potentially disruptive influences are observed and avoided. And should the checkweigher ever be relocated or moved then this should be carried out in line with a clear procedure.

The intent of this white paper is to point out the six most important aspects which help to extend the service life of dynamic checkweighers, maintain consistent quality and ultimately contribute towards greater efficiency profits.

In-depth knowledge pays

Some simple rules can make a difference

2 6 Golden Rules to Increase the Efficiency and Service Life of Your CheckweigherMETTLER TOLEDO Garvens White Paper – www.mt.com/garvens-gold

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les 2.1 A good start – Proper commissioning

Precision industrial weighing systems increase process quality and productivity. However this is dependent on correct installation, integration, setup and performance testing with corresponding documentation. Moreover, personnel must be familiar with the proper procedure for operation and maintenance.

Timely production readiness, especially in the installation phase, requires care and product experience. Only a weighing system that is correctly installed, adjusted, connected, tested and calibrated according to the specific application requirements will be able to fulfill its tasks. Today, only qualified and authorised technicians are capable of installing a modern checkweigher. For the equipment supplier's experts, certification of technical knowledge should not present a problem; for employees from one's own company, however, this is not always so clear cut. An expert is needed, especially when it involves connection to data and control networks for seamless integration. Connection to peripheral devices and components to ensure that required functions are provided also requires skill and expertise.

It helps when all the pieces of the puzzle are provided. During the installation phase, "completeness" is particularly important. In most cases, those involved assume that everything needed for the installation has also been delivered. Confidence in suppliers is certainly great; nevertheless, a little check can prevent much delay. Although with standard configurations it is rather rare that something is missing, a completeness check should be obligatory for custom-made products. A comparison of the order form, delivery note or order confirmation with the delivery quickly indicates whether a query is necessary. Otherwise, technicians who have to wait for missing parts can easily turn into an additional cost. Complete documentation for the new checkweigher must also be considered. Under certain circumstances, a whole series of documents may be necessary.

Documents that should be available during the installation phase:

• Operating instructions (operating manual), in some cases in several languages

• Documentation about customer-specific solutions (in some cases in several languages)

• EC Declaration of Conformity (CE certificate where applicable)

• Other certificates for special solutions/special parts

• Documentation relevant for official verification (MID Declaration of Conformity)

• Mechanical/electrical system diagrams

Checkweighers should be installed in conformity with the regulatory requirements of the respective country. The Measuring Instruments Directive (MID) is applicable for the countries of the EU, the EFTA and for Liechtenstein, Iceland, Norway and Switzerland. Its contents describe the processes and responsibilities for production and commissioning of, among other things, checkweighers. The responsibility for the initial verification, which was previously performed by the national authorities, rests with the equipment supplier since these provisions went into effect (30.10.2006). With the MID conformity assessment, the authorised equipment manufacturer confirms that the checkweigher conforms to the national regulations and the respective tolerances. The result is certified (MID Declaration of Conformity), documented and marked by a seal of approval. The original products to be weighed must be available for on-site testing within the company. The company then has to arrange all subsequent verifications with the responsible Weights and Measures Services.

Note: Proper installation ensures improved performance capability and thus the profitability of your investment..

Top tips:+++ Make sure the installation is performed by certified experts.+++ Make sure the documentation of the installation is complete, especially in the case of special designs.+++ Make sure applications for subsequent verifications are submitted in a timely manner. The MID Declaration

of Conformity replaces the initial verification by the national authorities; it does not replace the subsequent verifications.

2.2 Well prepared – Optimum training

Those who wish to achieve optimum productivity in production nowadays cannot afford to overlook the "human factor". Unfortunately, this often occurs, especially with regard to technically complex systems with their advanced automatic control systems. After all, correct handling and operation of high-precision devices has a significant effect on availability and performance. Equipment supplier's service statistics clearly show that many service calls are caused by operator errors.

Although the menu-driven operation of modern checkweighers is almost intuitive, it is important to implement targeted training measures right from the start. Careful handling of precision instruments extends their service life and ensures a continuous production process. Every machine operator must receive basic training that takes into account operation, care and maintenance. Knowledge of product setup and changeover as well as the procedure for erroneous rejections or unexpected machine stops must be communicated to those involved before the start of production, ideally during the installation phase. Manufacturers of dynamic weighing systems such as checkweighers recommend that this knowledge is refreshed on a regular basis..

The required basic knowledge differs from employee to employee:

Knowledge Employees working with the checkweigher

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Performing product changever X X X X

Performing product tests following changeover X X X X

Explanation of the components X

Creation of a log file X

Explanation of the E-drawing X

Performing a quick troubleshooting operation X

Determining the waterproofness of the individual parts of the checkweigh. X X

How and by what means the individual components are to be cleaned X

Knowledge about the verification and the responsibilities involved in verification X

Knowledge about how the statistics work X X

Knowledge about the tests to be performed by QA X X

Creation of new products (parameterisation of product setups) X

Explanation of the advantages of maintenance by manufacturer‘s technicians X

In addition to basic training equipment suppliers offer a broad selection of training options. These range from webinars to in-house courses. The subject matter extends from basic operation to specific applications so that you can make the most of your equipment while avoiding costly mistakes.

Top tips:+++ Establish a plan for basic knowledge training during the installation phase+++ Establish time intervals for supplementary regular training+++ Check the knowledge of employees working with the checkweigher against a checklist at irregular intervals




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les 2.3 Well maintained – It is the small things which make all the difference

During investment planning for a checkweigher, the ambient conditions in the location of use and the product characteristics must be taken into account by the equipment supplier to ensure the correct design. These factors have a decisive influence on the precision of the measuring instrument. Indeed, without correct and regular care, even the best machine configuration is of little use. Contamination with dirt, incorrect or lack of care for the various components can result in fatal consequences. These range from a succession of machine stoppages through inaccurate weighing results to reduction of the machine's service life. Often all it takes is for the operators as well as the production supervisors to heed a few careful instructions in order to prevent costly damage.

Not all checkweighers are alike. Even though many of the basic aspects of care are the same for all machines and manufacturers, precise measuring instruments do differ significantly depending on areas of use and specific application requirements. The important thing is that the relevant checkweigher and its material and processing characteristics are understood by the employees.

Which characteristics are worth noting?

• Construction materials – For example, aluminium, stainless steel or other coated materials need to be treated differently.

• Different surfaces Screens susceptible to scratching must be maintained differently than elements and components made of metal.

• The conveyor unit – Conveyor belts or chains require special attention, because soiling can very easily result in excess vibration, wear and weighing inaccuracies.

• The cabling – The cabling on measuring devices generally requires particular attention. Loose cables that are lying around can be tripped over and loose plug connections can be inadvertently disconnected. Addressing this will reduce accidents and unplanned stoppages for irritating fault finding.

• The peripheral devices – Devices that are connected to a checkweigher, such as cameras, printers and other product handling components must be handled according to the equipment supplier's instructions.

• The sorting device/rejection unit –Sorting devices and rejection units require a watchful eye. Jams and malfunctions can occur at these points especially when product characteristics require special handling.

Spoilt for choice: selecting the right cleaning products. Not all cleaning products are appropriate for the various materials and surfaces used. It must be determined on a case by case basis whether just water or a special cleaner should be used. Most companies use standard cleaning agents that they also use for other machines – these products are available in the company and consequently are also used for checkweighers. Always consult the relevant manufacturer with regard to which cleaning agents can be used on which parts, even before the checkweigher is installed. They will be able to offer immediate advice as to whether the currently used "home remedy" can be used. In addition: Reputable equipment suppliers will never make a mandatory specification without clear justification.

Regular cleaning routines are critical. Companies are well advised to establish regular cleaning intervals and to establish and adhere to the associated cleaning procedure. Equipment supplier's recommendations are useful in developing a company-specific cleaning checklist for the checkweigher. With these guidelines, you can ensure that all requirements of your system are satisfied – an essential element for ensuring a seamless production run.

Standards greatly simplify care and protect against damage. Acknowledged industrial standards such as the protection class classification of the National Electrical Manufacturers Association (NEMA) describe



the environmental protection required for the controllers, components and housings of checkweighers. This enables you to identify the intensity with which classified parts may be cleaned. The better the core pieces of a checkweigher are protected by the equipment supplier, the less prone to interference such an instrument proves to be during its service life.

Note: Look for suppliers who offer components with a high IP class rating as standard – for example IP69k for weigh-cells and IP65 for motors..

A brief overview of the established protection classes:

• IP 30 – Prevents ingress of objects >2.5mm (tools, thick wires, etc.).

• IP 54 – Ingress of dust is not entirely prevented, but it will not enter in sufficient quantity to interfere with the satisfactory operation of the equipment. Water splashing against the enclosure from any direction will have no harmful effect.

• IP 65 – No ingress of dust. Protected from water jets. Water projected by a nozzle against enclosure from any direction shall have no harmful effect.

• IP 66 – No ingress of dust. Protected from powerful water jets. Water projected in powerful jets against the enclosure from any direction shall have no harmful effect.

• IP 67 – No ingress of dust. Protected against immersion up to 1 m. Ingress of water in a harmful quantity shall not be possible when the enclosure is immersed in water under defined conditions of pressure and time (up to 1 m of submersion).

• IP 69k – Standard DIN 40050-9 extends the protection for high-pressure, high-temperature washdown ap-plications. Such enclosures must not only be dust tight (IP6X), but also able to withstand high pressure and steam cleaning. The test specifies a spray nozzle that is fed with 80°C water at 8 – 10 MPa (80 – 100 bar) and a flow rate of 14 – 16 l/min. The nozzle is held 10 – 15cm away from the tested device at an-gles of 0°, 30°, 60° and 90° for 30 s each. The test device sits on a turntable that rotates once every 12 s (5 rpm).

Prevention is always better than unexpected maintenance. Unforeseen maintenance results in

costly downtime. This cannot always be avoided. However, through preventive care and careful handling of the various parts of a checkweigher, these cases can be substantially reduced. If wear parts are replaced at the intervals recommended by the equipment supplier and the cleaning intervals are observed, the risk of excessive downtime can be demonstrably minimised. Car drivers who replace both headlight bulbs when only one has failed prevent additional disruptive failures in the near future by taking into account the overall product service life of the light bulbs.

It should go without saying that the machine should be treated with care. Although checkweighers are sturdily constructed in order to meet high requirements in everyday production, incorrect care can have severe consequences in the long run. Experience has shown that, time and time again, sensitive conveyor belts are treated incorrectly. The use of coarse brushes, scrapers or aggressive cleaning agents can lead to serious damage. In many cases deflection rollers are, in complete contrast to supplier's instructions, greased and

90o

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10-15cm


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les conveyor chains are not treated with the specially provided oils. Regular instruction, e.g. on the part of QM

management or line management, easily prevents such neglectfulness and averts economic damage.

2.4 Well observed – Seeing and acting go hand in hand

Humans perceive their surroundings with their senses. Sight is the most important sense for humans. It is comprehensive and processes extremely quickly. In everyday life, we sometimes refer to our ability to "recognize at a glance". Very often we recognize within fractions of a second whether something is OK or not OK. It is also worth applying and teaching this ability in the workplace. In order to recognize a defect or possible damage to a checkweigher, frequently all it sometimes takes is a glance. It helps if operating personnel have been told what they should pay attention to during the commissioning of a machine. However, ideally this training should be performed regularly.

Standardised procedures in the event of a defect are a MUST. If errors occur on the checkweigher or the peripheral devices, each employee must know exactly what to do. A clearly defined and structured escalation process then ensures that everyone involved reacts correctly in a problem situation. This means, first of all, that a system failure or malfunction is corrected as quickly and economically as possible. In addition, it increases the responsibility of each individual for the checkweigher. Thus, the risks connected with a system malfunction are reduced over the long term.

Regular visual inspections are everyone's concern. In practice, the visual inspection task is very often assigned only to the operator. He should look carefully for any dirt or signs of damage especially during cleaning. However, this may not be sufficient in the highly complex applications. There is a risk that the visual inspection will not be performed conscientiously. One solution is random sampling checks by the QA manager. This serves to repeatedly stress the importance of this preventive measure. However, in order to cover all eventualities, a pre-determined schedule is the best option. It provides instructions regarding which parts are to be checked, how often and by whom. This minimises the risk of potential causes of damage being overlooked. Checklists on which the particular activity must be checked off have proven to be very practical in the workplace. Checkweighing suppliers are glad to assist in drawing up such checklists.

2.5 Well maintained – On the safe side – thanks to expertise

Three ways to maximize uptime? Minimising the risk of failure and detecting malfunctions early has an automatic effect on the uptime of a checkweigher. Preventative action can be carried out in two ways: On the one hand, chekweigher manufacturers have experienced service technicians that are available at any time to lend a hand in case of emergency. On the other hand, a company can effectively prevent such emergencies through implementing measures of its own. Complete documentation of all service visits and work performed should be the norm. In this way, evidence can be provided to authorities and end customers at any time as a means of quality assurance. To cover all bases, three approaches have proven to be effective in practice:

• Use the service offerings from the supplier – A number of suppliers offer service contracts which include various services such as inspections, service calls and replacement parts. Also check the various offers for service reaction time, inclusive services, price discounts for spare parts and remote diagnostics options. Re-mote diagnosis/remote maintenance reduces costs because anomalies are detected earlier, so technicians are well prepared in advance for any required visits and problems can be corrected more quickly.

• Preventive maintenance – Like all precision instruments, checkweighers must also be properly maintained in order to guarantee optimum service. Preventive maintenance service which includes preemptive replace-ment of wear parts and fine tuning if required is the best way to ensure that your checkweigher is always in top condition and performs to the required standards. Ideally, preventive maintenance plans are designed to maximise availability and should be drawn up with help from your equipment supplier. The in-house technician – or the external maintenance service of the sup-plier – takes action automatically at the established time intervals (e.g. number of machine operating hours).



• 3. Tests and performance reviews – Self-testing is the easiest way to ensure the proper performance (and availability) of your equipment. In addition to the scheduled service intervals, self-testing gives you added se-curity that things are running the way they should, in line with the original specification as well as providing advance warning of issues. In order to conduct reliable self-testing, however, correct test weights and procedures are required. Check-weighing suppliers offer all necessary certified test weights as well as proven standard testing procedures. Seek advice from the supplier's experts on establishing optimal self-testing intervals and processes.

Note: Treat the checkweigher as you might treat a new car. Maintain the checkweigher according to a logbook. This provides documentation that all service intervals and maintenance work have been performed regularly by the technici-an and serves as proof of good condition.

2.6 Well situated – Precise weighing requires defined site conditions

The precision of a checkweigher can be influenced by the production environment and the characteristics of the product being produced. These two aspects should always be treated as a priority during investment planning in consultation with the supplier. Only then can the design be exactly matched to the particular operating requirements. However, in business practice, it very often turns out that the checkweigher will need to be repositioned or new articles must be weighed that differ substantially in weight and characteristics from the ones previously produced. In these cases the influences acting on the checkweigher may change dramatically from the original specification. This may result In critical cases not only in inaccurate weighing results, but it can also cause damage to the measuring instrument and easily shorten its service life.

Highly sensitive weighcells, in particular, can be susceptible to change. A change of installation location may involve changes in envirnmental conditions. These changes can be:

Temperature fluctuations and humidity: Checkweighers that are not specifically designed for fluctuations in temperature and humidity are at risk when confronted with such conditions. The effect: changing temperatures can distort measured results. Ingress of foreign matter, such as condensate, can damage the weighing cells.

Dirt and dust: Increased accumulation of dirt or dust may result in deposits on the weighing platform or the weighing belt. The effect: Weight fluctuations and a frequent re-zeroing hinder the manufacturing process. The solution is to shield the weighing area and ensure that the production areas involved are kept clean.

Vibrations and oscillations: There are a large range of sources of external vibrations that can exhibit negative effects as "noise". The causes range from opening and closing containers in the vicinity of the checkweigher to unstable products on the conveyor belts. This results in distortions in the measured results. The solution is to decouple the checkweigher, regularly monitor the surrounding area and ensure that special product handling features are included in the design specification.

Air flows: Highly sensitive checkweighers that need to operate to fractions of a gram register draughts of air as a weight deviation. Most draughts of air often occur for completely trivial reasons and can lead to problems. An open door or window is sufficient; even a quick hand movement in the vicinity of the weighing platform. The effect: The results are easily distorted. Attention and caution in the production environment can help to prevent this.

Electrical noise: Electrical devices and machines are capable of producing frequency interference, electromagnetic discharge or other types of interference. Although this is a very unlikely occurrence under extreme conditions certainly possible. The effect: this can disturb the data and weighing processes of sensitive checkweighers and stop them from working correctly. Shielding measures and responsible handling of electrical or electronic devices in the vicinity of measuring instruments provide a remedy.


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les Caustic substances: If checkweighers are implemented and set up close to locations in which aggressive

substances are used, there is potential for serious danger. The effect: Components can be destroyed. Remedial measures in such cases should always be discussed with the manufacturer.

In many cases, unintended and improper operation or treatment of checkweighers are causes for damage and reduced precision. Leaning on parts of the checkweigher, walking on a weighing belt (Unbelievable but true – this is statistically the main cause of weighcell damage through overload!)or excessive tightening of screws is increasingly observed in practice. This can easily result in damage. However, other activities also lead to unexpected results: If – due to production changeover – products are weighed that are substantially heavier or larger than intended for the original design, it may result in damage. This is because the motor, the mounts or the weighcell are strained more intensely than expected and wear faster.

The weakest link in a production chain sets the pace. This observation can be universally applied to almost every facet of life more so in intensive production environments. On this closing point all checkweigher manufacturers agree, a checkweigher as a high-precision instrument should never be the weakest link in the chain. A new machine in the production line that enables higher throughput may be a source of problems: If the line speed is increased to take advantage of the new equipment it may cause unexpected wear and tear on the checkweigher as well as many other production line machines. You should never subject your checkweigher to conditions above the initial design specification and performance values. Working on or above the limit is not good: for neither the person nor the machine.

3. More detailed information

Checkweighing software compendium The checkweighing software compendium describes software functions and options for achieving easy

navigation as well as optimisation of the checkweigher system. It supplies a comprehensive overview of the checkweigher models in the X series. The compendium can help producers, for example, shorten the changeover times when changing the production

line. In addition, there are solutions for improved fill quantity checking, perfect product transport and the greatest possible data security. www.mt.com/garvens-software

Guidelines for weighing technologyCreating an effective checkweighing program

The Garvens guideline "Principles of Checkweighing" is recommended as a reference document. It offers insight into all aspects of checkweighing, starting with the basic principles up to the implementation of a comprehensive checkweighing program.

This 70-page FREE guideline helps producers as a companion document for setting up this sort of weighing program, and is required reading for everyone who has anything to do with checkweighing systems.www.mt.com/cwguide

CalculatorsROI calculator for inline checkweighersThis calculator helps you to work out the amount of savings you can achieve by minimising overfilling and waste. Including sample calculation.www.mt.com/garvens-roi

Manual or in line weighing? Comparison of manual and dynamic weighing This calculator helps you to decide whether replacing a static scale with a dynamic scale would be more profitable for you.www.mt.com/garvens-dynamic

White papersOverall Equipment Effectiveness (OEE)This white paper provides a detailed description of the overall equipment effectiveness and demonstrates, using a simple calculation, how you can increase productivity at a low cost.www.mt.com/garvens-oee

Principles of hygienic design This white paper covers all aspects of the hygienic design of checkweighers. The last chapter describes a tool that helps you to assess hygiene requirements.www.mt.com/garvens-hygiene

Optimisation of filling systemsThis white paper relates to typical problems with filling, and offers tips and solutions for optimising the fill quantities – this has a direct effect on quality and cost-effectiveness.www.mt.com/garvens-filler

Total Cost of Ownership (TCO)This white paper explains in detail the most important components of total cost of ownership and describes in detail how to calculate the TCO including potential savings and typical cost drivers.www.mt.com/garvens-tco

On-demand webinarsThose who are interested can access on-demand webinars, with flexibility around the clock. You can obtain specific information about applications and products, learn about everything related to trends in the sector and standards, and obtain useful and informative illustrations.www.mt.com/pi-ondemandAvailable webinars on checkweighing:

The European Directive 2004/22/EC (Measuring Instruments Directive, MID)

Maximise your profits through intelligent weighing technology

High performance checkweighing for an optimum overall equipment effectiveness

Pharmaceutical serialisation – selection of the right equipment suppliers

Weight measurement for the improvement of your products and processes

www.mt.com/garvensFor more information

Mettler-Toledo Garvens GmbHKampstrasse 731180 Giesen Germany

Telephone +49 (0) 5121 933-0Fax +49 (0) 5121 933-456E-mail [email protected]

Subject to technical modifications.© 2012 Mettler-Toledo Garvens GmbH

Contact:For more information about checkweighing solutions please contact your local METTLER TOLEDO representative.

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