ncreasing the productivity of aglass plant involves more thantechnology and innovation.

Although both are critical suc-cess factors, neither technology norinnovation is enough. The key toprofitability is a combination oftechnology and innovation appliedin proven, systematic methods,as in Pack+, a new Advanced Ser-

vices product from Emhart Glass.The Pack+ service involves the

use of Six Sigma methodologies,together with the application ofEmhart Glass-developed advancedtechnology, and its experiencedstaff of production and productspecialists. By approaching pro-duction improvements in this sys-tematic way, Emhart Glass works

closely with the customer to findthe root cause of problems andwastes less time chasing non-critical factors.

Because glass container forminginvolves many interrelated vari-ables, there is seldom one factor that– if resolved or improved – willresult in full optimization of the pro-duction process. A strict fact-basedmethodology is required to ensurethat the root causes of problems arefound and rectified, rather thantrying to patch or quick-fix theprocess, which may result in wast-ed effort or only temporary, non-sustainable improvements.

Pack+ follows a six-step, SixSigma-based methodologydesigned to make changes basedon fact, not assumption:1. set the scope and mission of

the project;2. conduct an audit to get facts

and measure current perfor-mance;

3. review the findings and deter-mine next steps;

4. confirm the hypothesis;5. implement the improvements

and verify success; and6. sustain the improvements.

With this process, as well asnew, proprietary advanced tech-

Robert L. Bourgeois*

EMHART GLASS

BY MEANS OF ITS ADVANCED SERVICESPROGRAM, EMHART GLASS HAS HELPEDGLASSMAKERS WORLDWIDE ADDRESSSPECIFIC CONTAINER PRODUCTION ISSUES.THE COMPANY NOW PRESENTS THE NEXTSTEP - THE PACK+ - A COMBINATION OFADVANCED SERVICES PROGRAMS,PROPRIETARY TECHNOLOGIES, AND ANEXPERIENCED STAFF OF PRODUCTIONSPECIALISTS. BY APPLYING SIX SIGMAMETHODOLOGIES, PACK+ FINDS ANDRESOLVES ROOT CAUSES OF PROBLEMS.

nologies, Emhart Glass has usedthe Pack+ service to improve theproductivity of lines at a numberof glass plants worldwide.

Emhart Glass’ advanced tech-nologies, such as Virtual Model-ing and Cycle Optimization, pro-vide more precise solutions, whilethe company’s experienced staffof service engineers, bottle mak-ers, tradesmen and outside con-tractors, provide the means forimplementation. By means ofPack+, Emhart Glass now is ableto offer an expanded array ofAdvanced Services to the glasscontainer industry.

FOREHEARTH MODELLING

The Forehearth Modelling ser-vice can improve efficiency in theworking end and forehearth bycomputationally testing the sys-tem to optimize firing and controlstrategies to increase performance.Emhart Glass engineers generate athree-dimensional computationalfluid dynamic model that can sim-ulate the glass conditioning processin the systems used to manufacturecontainers. The model is then usedto optimize operation by antici-pating temperature distribution,pressure losses, and velocity pro-files, while simulating the effectsof internal and external radianteffects, steady state, and transientvortex rolls, as well as the heatlosses through the refractory andinsulation surrounding the channels.

MOULD DESIGN VALIDATION

The Mould Design Validationservice helps reduce the time need-ed for proofing the parison shapeon the IS new generation machine.Computer modelling techniquesallow bottle makers to predict theperformance of new mould designs.Ideas for improvement of the pari-son shape or mould coolingmethodology are computational-ly tested before final test andapplication on the machine. This

program allows the optimizationof the mould cooling system andblank mould design, resulting ina container that is capable of meet-ing strength requirements while uti-lizing the least amount of glass.

CONTAINER STRESSANALYSIS

The Container Stress Analysisservice uses computational tech-niques to evaluate the response ofa container design to thermal shock,impact loads, internal pressure,and vertical loads. Design attributesof a container, such as wall thick-ness distribution, height, push-upheight, and inside knuckle dimen-sions, all affect the inherent strengthof a container. By coupling form-ing simulations with strength analy-

sis models, it is possible to devel-op solution strategies to identifyproblem areas and regions of poten-tial container failure. This enablesthe bottle maker to optimize theblank and blow mould designsbased on the final container strengthrequirements. In addition to iden-tifying problems with a currentcontainer design, final productstrength analysis can identifyregions where a container has beenover designed. This can lead tosignificant savings of energy andraw materials through light weight-ing. Combined with Emhart Glassforming modelling, strength analy-sis provides a powerful tool that canbe used to design a container to meetall strength specifications with theminimum amount of glass.

BLANK MOULD COOLING

Computer based forming modelling programs. In this example, numer-ical modelling programs were used to optimize blank mould cooling bychanging the focus from cooling the mould to focusing on cooling the glass.

ALAN FENTON “EXAMINING” A BOTTLE

Project Engineer,special projects,“examines” abottle from aproduction lineduring a Pack+line audit

MOULD COOLINGThe Mould Cooling service

recommends the optimal mould-cooling configuration, based on thecontainer being made, by chang-ing the mould-cooling paradigmfrom a focus on cooling the mouldto a focus on cooling the glass.Depending on the size of the con-tainer and the forming process,Emhart Glass can recommend andsupply a cooling system that willtake advantage of the thermaltimes inherent in the formingprocess, and produce a parisontemperature distribution that gives

FEEDER MODELLINGThe Feeder Modelling service

can show variations in gob pro-perties and computationally deter-mine the link between the fore-hearth exit plane and the gob. Con-trol algorithms are then developedto compensate for these varia-tions. Once a link has been devel-oped for a particular feeder/forehearth configuration, fore-hearth control algorithms can bedeveloped to push the forehearthexit plane temperature toward a dis-tribution that minimizes thermal,viscosity, and gob weight variations.

the strongest container for a giv-en weight. Combined with theEmhart Glass forming modellingcapabilities, specifying the correctmould cooling strategy for con-tainers can lead to significantcontainer weight reduction with-out the loss of container strength.

CYCLE OPTIMIZATIONThe Cycle Optimization ser-

vice helps solve the bottle maker'sultimate problem: the balancing actof compromises made indirectly byadjusting individual event anglesto manage blank contact, mouldcontact, and all other thermal form-ing steps to achieve the desiredresults. Trained bottle makers,with the use of the new EmhartGlass Cycle Optimizer softwareprogram, can directly manipulatekey thermal forming durations tofind the best possible, correctlysequenced, and collision-free jobtiming. The results are formingprocesses that are optimally tuned,machine cycles that are minimized,and speeds of non-critical servo-mechanism motions that arereduced. Typically, the effects of theoptimized job are better ware qual-ity, increased per cent pack,improved production rate, all ofwhich are accomplished while pre-venting mechanism collisions,reducing downtime, and cuttingmaintenance costs. The Cycle Opti-mizer, a key tool that can be usedas part of Pack+, can help increasebottle makers’ productivity andallow them to focus on solvinghigher-level production problems.

GOB FORMATIONThe Gob Formation service uses

existing computational methodsto investigate how various feederdesign and operating parametersaffect gob shape and weight. Thenumerical simulations show theformation of the gob at the feederand the transfer of the gob to theblank mould. A key area of inter-est in these studies is the effectof the feeder plunger motion and

PACK+ - OPTIMIZING SOFTWARE PROGRAM TO INCREASE LINE SPEED

a high level of defects associatedwith “stuck glass.” By using thenew fact-based problem-solvingapproach of Pack+, the team wasable to precisely determine theroot cause to batch composition andresolve the issue. If the team hadtaken a more traditional approach,focussing on trying to adjust themachinery and forming process,they would have wasted days andnot definitively solved the problem.

At a second site, the goal was toincrease pack rates above 92 percent and decrease down time to lessthan 1.5 per cent. This plant hadbeen experiencing pack rates of 88per cent and downtime of almostthree per cent. After the Pack+team investigated the line, theyfound a number of critical machineand process issues that could thenbe systematically resolved. Packrate and downtime statistics dra-matically improved, surpassingthe initial goals, outperformingthe performance of sister linesmaking same or similar containers.

At another site, the joint cus-tomer/Emhart Glass Pack+ teamdetermined that there were nomachine or equipment-relatedissues, but rather a combination ofmould design and set-up issues.With assistance from an Emhart

Glass bottle maker and valida-tion of mould design via com-puter-based modelling, pack rateswere significantly improvedbeyond target levels.

Pack+ is more than a productor a service. It is both. Unlike asingle product or a particular ser-vice, Pack+ is a custom-designedpackage of products, technology,advanced services, and systematicmethods, configured to resolvespecific problems, optimize thecontainer forming process, andincrease profitability. Pack+ isanother way Emhart Glass isapplying a customer first, quali-ty first focus to the products andservices it supplies to the glasscontainer industry.

*Training & DevelopmentCoordinator

Emhart Glass - USA

CYCLE OPTIMIZATION SOFTWARE, ONE OF THETOOLS AVAILABLE IN THE PACK+ SERVICE

gob transfer equipment on gobshape. By evaluating the extentand manner to which feeder andtransfer equipment design affect gobshape and weight, a systematicmethodology to control these para-meters is developed. Insights gainedfrom the models are used to devel-op new gob forming and transferequipment that allow greater gobshape and weight control. Thissystem helps eliminate containerweight and thickness variations, andreduces the number and severity ofdefects created during the con-tainer forming process.

VIRTUAL FORMINGThe Virtual Forming service

uses proprietary numerical modelsto analyze blow & blow and press& blow processes to determine thesensitivity of the final container-to-process parameters, thus improv-ing the container design at reducedcost and time. All stages of theprocess are modelled, and the resultof each unit is transferred and usedas an input for the next unit to pre-dict the final bottle thickness dis-tribution. In addition to specificthermo-mechanical coupling capa-bilities, "mesh-to-mesh" interpo-lation and remeshing techniques areavailable to allow a continuation ofthe calculations in spite of verysevere mesh deformations. Thesepowerful modelling capabilitiessuccessfully address all criticalstages of the glass forming process.

PROVEN RESULTS The new Pack+ service is a

package of all or some of theabove programs, each employedas determined by the systematicinvestigation that is integral tothis new service. To date, combi-nations of these services havebeen used at various customersites resulting in significant gainsin productivity.

At one site, Emhart Glass pro-duction specialists were able toresolve a chronic defect problem.The customer was experiencing

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