content · 2019. 11. 6. · content presentation of technica family business company profile end to...
Post on 14-Sep-2020
0 Views
Preview:
TRANSCRIPT
Content
Presentation of Technica
Family business
Company profile
End to end solutions
Innovative solutions
Light weight bottle storage solutions
Multi-product packaging solutions
Pallet inspection solutions
Auto truck loading solutions (single cases)
IOT
INNOVATIONS in Packaging Solutions
1982 Foundation of Technica as a local family business. Workshop: 76mas a local family business.
Staff: 4 Market: Local 2018 Technica has become a company with global reach. Factory Built Area: 7,500m Land Area: 15,000m Offices area 1,500m Staff: 200 Market: 36 Countries Branches: 6
Growth story
Technica a family business
INNOVATIONS in Packaging Solutions
Technica a family business
His excellency, the President of the republic of Lebanon, General Michel Sleiman, delivering the LEA award to Technica GM, Tony Haddad in 2010 & 2013. This is administered by the European community to companies meeting European excellence standards.
Technica was recognized with the 1st runner up prize for the GHWP Award in London. We used this award as a platform to refine and improve our system, and to spread the concepts of the GHWP in our community.
GHWP Award 2013 Top 500 growth 2012 Lea Award 2010/2013 GHWP Award 2014
Technica was recognized for the second time with the 1st runner up prize for the GHWP Award in Shanghai.
Technica was selected as one of the fastest growing companies in the Middle East. Ranked 7th in Lebanon.
Technica was recognized with
Top 500 growth 2012
Technica was recognized for the Technica was selected as one of
High Merit Award 2004
Technica received the innovation award from the Association of Lebanese Industrialists.
Awards
INNOVATIONS in Packaging Solutions
Creating Shared Value
Technica a family business
We installed solar panels to generate clean electricity (70KW).
We plant trees for our customers, 1700 trees planted so far in 3 years.
We recycle all our materials. We donated the waste sorting station to the municipality of Bikfaya.
INNOVATIONS in Packaging Solutions
Technica a family business
Creation of “Technica Academy” - Grow & share the knowledge. - Develop highly skilled and competent technicians and engineers to follow the technological
breakthrough. - Develop career plan for the team.
Technica Academy
INNOVATIONS in Packaging Solutions
Technica company profile
Headquarters & main manufacturing facility: Bikfaya, Lebanon
Manufacturing & service center for EU - Warsaw, Poland (2019)
Branches: Jeddah, Riyadh, Dubai, Stockholm, Cairo & Lagos
Local partners: Peru, Russia, South Africa, Pakistan, Bangladesh, South Korea & India Countries with executed projects
Technica in the world
INNOVATIONS in Packaging Solutions
Technica company profile
Key customers - Beverages
Key customers - Dairies
Key customers - water
Key customers - Food sector
Key customers - Petrochemical/Plastic
Key customers - Glass & Paper
Multinational customers
Our key customers
INNOVATIONS in Packaging Solutions
Technica company profile
Metal plate making factory Laser cutting machine for plate (Bystronic) CNC shears CNC bending machines Area: 1,000 m2
Metal plate division
INNOVATIONS in Packaging Solutions
Technica company profile
Components manufacturing factory CNC machines for turning, milling. Area: 1,000 m2
Components manufacturing division
INNOVATIONS in Packaging Solutions
Technica company profile
Second machine assembly area 65m long x 40m wide. Area: 2,600m
Mechanical assembly division
INNOVATIONS in Packaging Solutions
Technica company profile
Customer service division Customer oriented team - Installations - Maintenance & troubleshooting - Spare parts service
Customer service division
INNOVATIONS in Packaging Solutions
Technica end to end solutions
|
|
Complete lines for food & beverage Automation equipment • Empty bottles handling • Conveyors • Accumulation systems • Packers • Palletizers • Mixed Pallets • Truck loading Electrical solutions • Inspection systems • Scada systems • IIOT Robotic solutions Warehouse automation Partners ABB Accraply Amtech Ancra Baumer Gernep Kuka Lanfranchi Robopac Rockwell Siemens
INNOVATIONS in Packaging Solutions
Technica end to end solutions
Industry 4.0: • Use of smart sensors and advanced analytics to predict needed maintenance • Reduce unplanned downtime • Anomalies can be quickly detected and fixed • Maintenance schedules can be optimized to minimize disruption
IIOT Internet of things: Features: • Real time connectivity through cloud • Full visibility on running systems all over the world
Complete lines for food & beverage Automation equipments • Empty bottles handling • Conveyors • Accumulation systems • Packers • Palletizers • Mixed Pallets • Truck loading Robotic solutions Warehouse automation Partners ABB Amtec Ancra Baumer Gernep Graham Kuka Lanfranchi Rockwell Siemens
Electrical solutions• Inspection systems • Scada systems • IIOT
INNOVATIONS in Packaging Solutions
|
Technica end to end solutions
Complete lines for crate systems Automation equipment • Crate depalletizers • Crate inspection • Crate distribution • Crate packers • Crate palletizer • Pallet inspection • Pallet distribution Partners ABB KUKA PlasticBand Rockwell Siemens Unitech washers
|
INNOVATIONS in Packaging Solutions
Light Weight Bottle Storage System
• SILOs & Unscramblers: - SILOs create top load on bottle requiring heavier bottle weight - Extract system from the SILOs and unscramblers leave scratches on the bottles - Big volumes, with limited number of SKUs
Deficiencies of common bottle storage solutions (between blowing and filling)
• Bagging/debagging: - Require plastic bags which increases cost and create environmental problems - Limited stacking height
INNOVATIONS in Packaging Solutions
The Need
Light Weight Bottle Storage System
Bottles are stored in stackable trays to achieve the following: • Compensate the difference in capacities between blow
moulder and filler • Create a buffer to prevent the stoppage of the blow
molder which increases the OEE • Overcome the disadvantages of common storage
solutions: - Zero pressure on bottles - No scratches - Greater feasibility with multiple SKUs
Technica’s Light Weight Bottle Storage System
INNOVATIONS in Packaging Solutions
The Solution
Light Weight Bottle Storage System
Bottles are palletized in stackable trays at the discharge of the blower, to achieve the following: • Preserving their orientation.
• Trays take the stacking load - Zero load on bottles.
• Trays and pallets are nestable - allowing multilevel storage.
• After storage, pallets are fed to a de-palletizer where the
bottles are transferred from trays to the production line - Keeping their original orientation.
• Empty trays are circulated back to bottles palletizing cell.
Operation Process
INNOVATIONS in Packaging Solutions
The Concept Buffer Storage
• Conveyor system allows in-line operation blower to filler, when no storage is required
In-line Operation
Features Bottles keep their orientation
Zero load on bottles
Modular storage for different SKUs
Smooth handling of bottles
Traceability of bottles inside the trays
High stacking possibility and organized pattern
INNOVATIONS in Packaging Solutions
Light Weight Bottle Storage System
Features & Benefits Benefits No orientor required
Bottle weight can be reduced
Flexibility of multiple SKUs on the line
No scratches
Possibility of FIFO, data report and analysis
Small footprint in warehouses
INNOVATIONS in Packaging Solutions
Savings • Main savings are generated by the reduction of
the bottle weight.
• Payback Period can reach less than a year.
Standard 2L bottle: 40g
LWBSS reduced weight: 34g
Light Weight Bottle Storage System
Savings & ROI
Multiproduct Packaging
• Market trend is driving towards multiproduct packages.
• Mixed distribution centers, need to ship different SKUs
on the same pallet, as per preorder from market.
• High volumes are required in a limited time, in order to
have a short window to “Go to Market”.
• Manual mixing operation is slow and requires a high
number of labor.
• Errors and miscounts are frequent.
• The need of large space for the operation, especially for
high variety of SKUs & high capacity.
• Difficulty to track the preorder and to generate output
reports
The Need
The Problem
INNOVATIONS in Packaging Solutions
Multiproduct Packaging
• Automated system for mixing of various SKUs in
the secondary pack.
• Automated system for mixing various secondary
packages on one pallet.
• Savings in man-power and cost.
• Reduced space occupied.
• 100% error-free operation.
• High capacity, allowing very short “Go to Market” time.
• Squared and well-shaped pallets.
• System is connected to ERP, to receive preorders, and
generate production reports.
• IIOT platform on the cloud for online data collection and
remote analysis & storage of date
Solutions
Benefits
INNOVATIONS in Packaging Solutions
Multiproduct Packaging
Operation • 3 pallets in-feed for 3 different SKUs. • Delayering of SKUs on 3 tasks. • Single line each SKU. • Inspect, code and print on SKU. • Mix 3 SKUs in a single secondary pack. • Palletize the mixed pack.
Capacity • Up to 200 secondary packs/minute. • Man power: 1 forklift operator to transport pallet.
Reference System being developed for Danone Holland
The Concept (Tray Mixing)
INNOVATIONS in Packaging Solutions
Multiproduct Packaging
Operation
Capacity
Reference
INNOVATIONS in Packaging Solutions
The Concept (Pallet Mixing)
Reference System installed in Pepsi Jordan, in 2016.
Multiproduct Packaging
Operation • 5 pallets in-feed for 5 different SKUs. • Picking of full layer from pallet. • Palletizing the layer on the mixed pallet. • Stretch wrapping the mixed pallet. • Pallet composition received online from provider
via ERP system.
Capacity • 4 layers/minute. • Up to 40 pallets/hour, depending on mix. • Man power needed: 1 forklift operator.
Pallet Mixing Line (Pepsi-Cola)
INNOVATIONS in Packaging Solutions
Pallet Inspection System
• Stop the line & reduce OEE
• May cause serious accidents
• Generate losses
• Cause quality problems
Defective pallets must be removed from operation
INNOVATIONS in Packaging Solutions
The Need
Defective pallets
The Solution
• Highly customizable sorting criteria
• Wide range of supported pallets (types & sizes)
• Operation speed up to 375 pallets/hour
• Inline operation for single line
• Offline operation for the whole factory
Technica’s Pallet Inspection System
INNOVATIONS in Packaging Solutions
Pallet Inspection System
Checks the integrity, geometry and structural stability of your pallets
INNOVATIONS in Packaging Solutions
The Concept (wooden pallet)
• Remove of any loose debris to allow accurate inspection.
• Ensure bottom runners will not jam on the line.
• Crush down protruding nails without rejecting pallet.
• Check for missing planks, to ensure product stability.
• Measure by laser that length and width are within tolerance.
• Apply load to test carrying capacity.
Wooden Pallet Inspection
Pallet Inspection System
INNOVATIONS in Packaging Solutions
• Detect missing legs and connection ribs by a series of rollers.
• Detect fragile bands and legs by forcibly deforming them and
measuring deformation by laser beam.
• Two laser scanners, one from the top and one from the bottom,
generate a 3D cloud image of the pallet detecting the presence
or absence of objects as small as a rolling dice.
• Transducers to detect the deformation of the top ribs
Plastic Pallet Inspection
Pallet Inspection System
The Concept (plastic pallet)
Mandatory for Warehouse automation:
• To run with LGV/AGV.
• To fit in the racking/storage system without getting
stuck or damaged.
Improved quality/safety: • Sustained quality for products on the market.
• Image and appearances of product.
• Minimize product damage due to damaged pallets.
• Eliminate safety hazards.
Increased OEE: • Fewer stoppages to remove defective products.
• Less jams on the lines.
• Reduced maintenance and breakages.
INNOVATIONS in Packaging Solutions
The Benefits
Pallet Inspection System
INNOVATIONS in Packaging Solutions
• Can be installed inline with palletizer line
Offline Automated System
Pallet Inspection System
Destacker
Inspection of pallet
Good pallet stacker
Defective pallet stacker
In-line System
• Fully automated system, can be installed for the entire factory.
• Stack of empty pallets are fed to system.
• Pallets are destacked and fed to the line.
• System checks the pallet for defects.
• Defected pallets are rejected on a separate line.
• Good pallets and rejected pallets are stacked in separate stacks.
offline System
INNOVATIONS in Packaging Solutions
ROI
Pallet Inspection System
Sources of savings are generated by eliminating:
• Damaged finished products due to fallouts.
• Stoppage time of line to remove fallen products.
• Maintenance & repair costs due to breakages.
• Work accidents..
Payback can be less than a year, depending on volume and on
quality of available pallets.
Automatic Truck Loading with Loose Packages
• Loading with full pallets:
- Low vehicle fill rate (75%)
Deficiencies of common truck loading methods
INNOVATIONS in Packaging Solutions
The Challenge
• Loading with loose packages:
- Loading with loose packages:
- Slow operation (4h to load one truck)
- Manual process, labor intensive
- No traceability of product / control of load
- Ergonomic problems for heavy loads
Automatic truck loading with loose packages to capture all these benefits:
• No operators needed
• Vehicle Fill Rate up to 95%
• Filling time less than 50min per container
• Flexible to accommodate any type of packages
• System can work for loading or unloading containers
Technica’s Truck Loading Solution (Patent Pending)
INNOVATIONS in Packaging Solutions
The Solution
Automatic Truck Loading with Loose Packages
INNOVATIONS in Packaging Solutions
The Concept
Automatic Truck Loading with Loose Packages
Instead of loading single packages one by one into the container, our system
loads a complete row of packages
System has two operational modes, loading and unloading.
A tailored solution to address all the truck loading gaps
The Loading Cycle
INNOVATIONS in Packaging Solutions
• The load order is read through ERP
• Loading algorithm generates a pattern with the maximum fill rate
of the load order. Constraints can be added to have heavy loads
at bottom and in the front of the container
AI Software
at bottom and in the front of the container
AI Software
• Packages are de-palletized from the pallets and single lined on
branch conveyors
De-palletizing
• Packages are merged into the main line according to the
required sequence by the pattern
Load Feeding
Load Preparation
Automatic Truck Loading with Loose Packages
INNOVATIONS in Packaging Solutions
The Loading Cycle
Automatic Truck Loading with Loose Packages
Loading the container
• The SKUs are fed to the row forming device where they are stacked horizontally
• The row of SKUs is moved to the delivery device where they are transferred and
placed inside the container
Scanning of rows
INNOVATIONS in Packaging Solutions
The Unloading Cycle • System scans the position, orientation/angle, and height of trailer then identifies the bottom of
the row that will be picked
• The row of packages is pulled on the delivery device
• The delivery device transfers the packages to the row forming device where they are
dispatched one by one
Unloading The Container
• Single packages conveyed &segregated to the palletizing stations
Palletizing
Automatic Truck Loading with Loose Packages
INNOVATIONS in Packaging Solutions
Features & Benefits Features • Increase of fill rate of container to 95%, (typical fill rate
for pallets feeding is about 75%)
• Speed is one container every 45-50 minutes, instead of 4 hours, by manual loading
• No truck modifications
• System is reversible and can be used for loading and for unloading, automatically
• ERP system can be incorporated to the system
• Different types of secondary packages can be used: cartons, shrink packs, polyouter bags
• Accurate control of truck load, and count of each SKU in the truck
• Labor savings and better ergonomics for the workforce
• System is movable and can be used on multiple trucks.
Benefits • Increasing trucking capacity by about 20%
• Reducing loading cycle time and increasing time of trucks on the road
• Possibility to use rented trucks or sub suppliers
• Reduced time during unloading of containers
• Inventory control and for optimizing loads of trucks
• Production control and monitoring
• Versatile for all production SKU’s and universal
• Inventory control
• Lower TCO
• Elimination of lost time while truck is maneuvering and packing
Automatic Truck Loading with Loose Packages
INNOVATIONS in Packaging Solutions
ROI
Automatic Truck Loading with Loose Packages
INNOVATIONS in Packaging Solutions
The Pilot System
Automatic Truck Loading with Loose Packages
The automatic truck loading with loose packages has been developed for a multinational
company with roll out potential.
Due to confidential reasons the video of the prototype can’t be shared, however it can
presented on request.
Below is a snapshot taken during the FAT in our plant.
INNOVATIONS in Packaging Solutions
IIOT Concept
Industrial Internet of Things
Central and Remote Management Level (IIoT):
• Consists of a network of intelligent devices.
• Collects and shares huge amounts of data and reports through a central Cloud-based service.
• Data and reports can be accessed and monitored remotely.
• Doesn’t require human interaction.
Control and Automation Level (Machinery):
Can be integrated on Technica equipment as well as on other suppliers equipment.
INNOVATIONS in Packaging Solutions
Plant View
Displays all the lines’ status:
• The green dot indicates an error free.
production line while the red dot.
• indicates a fault production line.
Displays the data calculated at a plant level:
• OEE
• Energy Consumption.
• Production reports.
• Alarms and messages.
Industrial Internet of Things
INNOVATIONS in Packaging Solutions
Machine View
Ability to zoom in display data at machine level:
• Motors connectivity
• Overall events history
• Operator controls’ status
• OEE
• Energy consumption
• Motors’ Currents
• Motors’ Temperature
• Alarms & signals
• Events history
• Statistical reports
• KPIs
• Warnings & messages
Industrial Internet of Things
INNOVATIONS in Packaging Solutions
Industrial Internet of Things
Output reports
Alarm
s G
raphs N
otifications (em
ail/sms)
INNOVATIONS in Packaging Solutions
Impact of IIOT
Industrial Internet of Things
IIOT
Improve troubleshooting & safety Lower costs
Better service levels
Increase process efficiencies Higher productivity
Streamlined maintenance
© Copyright 2014 Technica All rights reserved. No part of this presentation in all its property may be used or reproduced in any form or by any means without a written permission.
top related