Tech Fest 2013 (Costa Rica)

Abstract Submittal Form

Submission TitleMega Pack Line Vip Project

Submission Type

Category

Submitting AuthorDaniel Calvo Camacho

Co-AuthorsJairo Barrantes

Abstract Content

Introduction/Background(1000 Char. max.)The Mega Pack VIP Project is intended to implement a more efficient packaging line in the Super Stiff, integrating the sub assembly operati of Hooping, Packaging and Boxing areas plus the installation and validation of an automated Pouch Sealer.

The area of hooping, packaging, sealing and boxing of Amplatz Super Stiff were detected subject to improvement in terms of efficiency since there were found idel times during production due to following a Kan Ban production flow, excess of labor executing non-value added activities and long cycle times.

Method(4000 Char. max.)The methodology was the following:

1) Integration of the different operations (Hooping, Packaging, Sealing and Boxing) was analyzed based on a simulation, setting the expected production output and cycles times in order to implement the project.

2) Since an automated band sealer was installed as part of the production line integration, a full process characterization (Tech Report 90826005) was executed in order to guaranty that the sealing process is capable and meets specification. Preliminay results obtained from the FAT were analized, then a DOE and a Confirmation Run were executed in order to release the process for validation. One of the main goals of this activity was to confirm one single operational process range for the two types of pouches currently used and avoid re-setting of the equipment during production orders changes.

Results(4000 Char. max.)1) As part of the production line integration, the main results are the following:

1.1) 51% reduction on product transportation. 1.2) Idle space increase in 711 sqft. 1.3) 7 direct labor reports were moved to other areas. 1.4) Estimate savings up to 88.1k US$.

2) In regards of the process characterization, the main results are the following: 2.1) Results from FAT were key inputs in order to have an optimization DOE and being able to set the optimum process ranges by a contour analysis. 2.2) One single operational range was identified to operate the equipment for the two types of pouches, eliminating potential down times because of setting parameters. 2.3) The process validation executed as per report 90825998 were concluded as satisfactory and the sealing process was released for production purposes.

Conclusions(1000 Char. max.)Mega Pack Project was an integrated VIP that let to implement a new production line concept and implement a new piece of equipment that provided results in different areas, such as:

1) Efficiency increase. 2) Reduction of non-added value activities: transportation reductions. 3) Reduction of labor. 4) Savings in terms of efficiency improvement 5) Successful characterization and validation of the sealing process following results obtained from FAT, execution of a DOE and capability analysis during validation.