changeover webinar
DESCRIPTION
Best practices for selecting different levels of Changeover technology. Learn key criteria in Changeover controls, layout recommendations, and accessibility considerations.TRANSCRIPT
How to Reduce Changeover Time with Conveyor Technology
The Conveyor’s Role in
Changeover Processes
Agenda
1. 1. Manual – Single Adjustment Changeover
Agenda
1. 1.
2. 2.
Manual – Single Adjustment Changeover
Manual – Multi-point Adjustment Changeover
Agenda
1. 1.
2. 2.
3. 3.
Manual – Single Adjustment Changeover
Manual – Multi-point Adjustment Changeover
Automatic Rail Systems
Agenda
4. 4.
1. 1.
2. 2.
3. 3.
Manual – Single Adjustment Changeover
Manual – Multi-point Adjustment Changeover
Automatic Rail Systems
Accessibility Considerations
Agenda
4. 4.
1. 1.
2. 2.
3. 3.
Manual – Single Adjustment Changeover
Manual – Multi-point Adjustment Changeover
Automatic Rail Systems
Accessibility Considerations
Best Practices for selecting different levels of technology5. 5.
Agenda
4. 4.
1. 1.
2. 2.
3. 3.
Manual – Single Adjustment Changeover
Manual – Multi-point Adjustment Changeover
Automatic Rail Systems
Accessibility Considerations
Best Practices for selecting different levels of technology
Layout Recommendations
5. 5.
6. 6.
Agenda
4. 4.
1. 1.
2. 2.
3. 3.
Manual – Single Adjustment Changeover
Manual – Multi-point Adjustment Changeover
Automatic Rail Systems
Accessibility Considerations
Best Practices for selecting different levels of technology
Layout Recommendations
Decision Matrix7. 7.
5. 5.
6. 6.
Criteria
Initial Cost□ $□ $$□ $$$Man Hours□ +□ + +□ + + +Adaptable
□ Yes
□ NoControls
□ None
□ Simple
□ Complex
$$$
$$$
PURCHASE COSTBRACKET PRICING
Less than $5,000
Between $5,000 - $15,000
Over $15,000
Criteria
Initial Cost□ $□ $$□ $$$Man Hours□ +□ + +□ + + +Adaptable
□ Yes
□ NoControls
□ None
□ Simple
□ Complex
CHANGEOVERMAN HOURS
Few seconds
Moderate – less than ½ hour
Many – over ½ hour
Per 100 / ft. of conveyor
+
++
+++
Criteria
Initial Cost□ $□ $$□ $$$Man Hours□ +□ + +□ + + + Adaptable
□ Yes
□ NoControls
□ None
□ Simple
□ Complex
Is the solution adaptable?
Criteria
Initial Cost□ $□ $$□ $$$Man Hours□ +□ + +□ + + + Adaptable
□ Yes
□ NoControls
□ None
□ Simple
□ Complex
CONTROLS
Manual Solutions
Initial Cost□ $□ $$□ $$$Man Hours□ +□ + +□ + + + Adaptable
□ Yes
□ NoControls
□ None
□ Simple
□ Complex
Tool – less bracketsP
PP
PQuick Set with Hand Knob Ratchet Handle
Manual Solutions
Initial Cost□ $□ $$□ $$$Man Hours□ +□ + +□ + + + Adaptable
□ Yes
□ NoControls
□ None
□ Simple
□ Complex
Tool – less bracketsP
PP
PRatchet Handle with Ruler Guide
Manual Solutions
Initial Cost□ $□ $$□ $$$Man Hours□ +□ + +□ + + + Adaptable
□ Yes
□ NoControls
□ None
□ Simple
□ Complex
Guide Rail Systems – Adjustable ZonesP
P
PP
Min - Max Pin-in-place system
Manual Solutions
Initial Cost□ $□ $$□ $$$Man Hours□ +□ + +□ + + + Adaptable
□ Yes
□ NoControls
□ None
□ Simple
□ Complex
Guide Rail Systems – Adjustable Zones
P
P
PPDrop – In Rail Systems
Manual Solutions
Initial Cost□ $□ $$□ $$$Man Hours□ +□ + +□ + + + Adaptable
□ Yes
□ NoControls
□ None
□ Simple
□ Complex
Guide Rail System – Adjustable Zones
P
P
PP
Flip – In Rail Systems
Manual Solutions
Initial Cost□ $□ $$□ $$$Man Hours□ +□ + +□ + + + Adaptable
□ Yes
□ NoControls
□ None
□ Simple
□ Complex
Guide Rail Systems – Adjustable Zones
P
P
P
P
Hand Wheel with Digital CounterHand Wheel Video
Manual Solutions
Initial Cost□ $□ $$□ $$$Man Hours□ +□ + +□ + + + Adaptable
□ Yes
□ NoControls
□ None
□ Simple
□ Complex
Guide Rail Systems – Adjustable Zones
P
P
P
P
Manual Solutions
Initial Cost□ $□ $$□ $$$Man Hours□ +□ + +□ + + + Adaptable
□ Yes
□ NoControls
□ None
□ Simple
□ Complex
P
P
P
P
Guide Rail System – Adjustable Zones
Layout Example - Manual
Layout Example - Manual
MASS FLOWNO CHANGEOVER
Layout Example - Manual
Hand Wheelwith Digital
Counter
Layout Example - Manual
RATCHETHANDLES
Layout Example - Manual
RATCHETHANDLES
Questions? Take our poll.
What is your primary reason for researching changeover solutions?
1. Increase in just-in-time production requirements2. Product line expansion3. To increase line-efficiencies4. Lean manufacturing corporate strategy
Accessibility
Access Lift Gate
Accessibility
Platforms
POLL RESULTS
To increase line-efficiencies
Lean manufacturing corporate strategy
Increase in just-in-time production requirements
Product line expansion
0 2 4 6 8 10 12 14 16 18 20
18
12
6
2
What is Your Primary Reason for Researching Changeover Technology?
Automatic Solutions
Initial Cost□ $□ $$□ $$$Man Hours□ +□ + +□ + + + Adaptable
□ Yes
□ NoControls
□ None
□ Simple
□ Complex
P
Single Sided
P
P
P
Pneumatic Drop-In Rail System
Automatic Solutions
Initial Cost□ $□ $$□ $$$Man Hours□ +□ + +□ + + + Adaptable
□ Yes
□ NoControls
□ None
□ Simple
□ Complex
P
Single Sided
P
P
P
Pneumatic Push-In Rail System
Automatic Solutions
Initial Cost□ $□ $$□ $$$Man Hours□ +□ + +□ + + + Adaptable
□ Yes
□ NoControls
□ None
□ Simple
□ Complex
PP
P
P
Dual Sided
Automatic Solutions
Comparing Pneumatic and Electric Cylinders
Pneumatic Electric
Changeover Equipment
Initial Cost□ $□ $$□ $$$Man Hours□ +□ + +□ + + + Adaptable
□ Yes
□ NoControls
□ None
□ Simple
□ Complex
P
P
P
P
GripperElevator
Hand Wheel
Gripper Elevator Video
Changeover Equipment
Initial Cost□ $□ $$□ $$$Man Hours□ +□ + +□ + + + Adaptable
□ Yes
□ NoControls
□ None
□ Simple
□ Complex
P
P
P
P
Case Elevator
Hand WheelCase Elevator Video
Product Considerations
Product Considerations
Product Considerations
Automatic Solutions
Automatic Solutions
POWERED DIALINDICATOR
Automatic Solutions
POWEREDDIALINDICATOR
Automatic SolutionsPOWERED
DIALINDICATOR
Automatic SolutionsELECTRIC
ACTUATEDAUTOMATIC
RAIL SYSTEM
Cost versus Man Hours
100 Feet of Straight Conveyor
$30 / hour Labor Rate
250 Changeovers Per Year
Cost versus Man Hours
100 Feet of Straight Conveyor
$30 / hour Labor Rate
250 Changeovers Per Year
Set Points
Cost versus Man Hours
BASELINE
108 Adjustment Points
$7,500 in labor
60 Min.
250 hrs. lost/year
Cost versus Man Hours
Level 1: RATCHET HANDLE
108 Adjustment Points
$5,625 in labor
$1,000 for the ratchet
handles
45 Min.
188 Hrs.Lost/Yr.
Cost versus Man Hours
Level 2: RATCHET HANDLE
With Pre-Measured Points
108 Adjustment Points
$3,750 in labor
$2,000 for the ratchet handles andpre-measured set points
30 Min.
125 Hrs.Lost/Yr.
Cost versus Man Hours
Level 3: RATCHET HANDLE
one side
54 Adjustment Points
$1,875 in labor
$1,500 for the ratchet handles andpre-measured set points
15 Min.
62 Hrs.Lost/Yr.
Cost versus Man Hours
Level 4: HAND WHEEL DIAL INDICATOR
One Side
3 Adjustment Points
$625 in labor
$22,500 for rail system
5 Min.
20 Hrs.Lost/Yr.
Cost versus Man Hours
Level 5: AUTOMATIC ADJUSTABLE
With Operator Push Button Station
1 Adjustment Point
$125 in labor
$27,500 for rail system
1 Min.
4 hrs.Lost/Yr.
Changeover White Paper
Download White Paper
Cost versus Man Hours
CHANGEOVER SOLUTIONS
10 YEAR Labor Cost Versus Purchase Cost
Manual Automatic
CO
ST
$
1 2 3 4 5 60
10000
20000
30000
40000
50000
60000
70000
80000
COST
LABOR
BASE
MANUAL
SET POINTS
ONE SIDE
HANDWHEEL
AUTO-MATIC
Questions?
Thank you for attending!
For more information, visit our website
www.nercon.com
Check out our blog!
Automatic Changeover Guide Rail Systems
Changeover White Paper