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

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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!

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www.nercon.com

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Automatic Changeover Guide Rail Systems

Changeover White Paper