Front End Performance

About IPS Mission Statement

“To provide state of the art engineering, technical and operational support and service to the packaging and

container manufacturing industries. Providing optimized solutions designed to effectively utilize current assets with the result of improved cost performance to our customers”

1.Services Supports customers to better use existing Capital and

Human Assets

Engineering, Operations and Integration

Support and Training

2.Products Developed to support effective use of assets

3.Design and Development Focus on technology to improve can making processes

About IPS Three (3) Main Areas of Business

About IPS Our Resources

15 Full time Employees 10 Languages spoken by IPS 11 Countries with IPS Representation 60+ Associates with a wealth of experience

• 15 with 30+ years can-making experience • 25 with 20+ years can-making experience • 20 Long-term operational can-makers • 21 Degreed Engineers • 10 Software Engineers • 7 Masters Degrees and 1 PHD • 3 Professional Engineers • 8 Millwrights • 2 Six Sigma Certifications

Our Customers

Definition of “Front End Performance” • Cup

• Trimmed Cylinder

• Bright or Washed Can

Back End performance problems due to Front End quality / defects

Examples of technical variables include: • Metal Quality and Proper Specification

• Cup…Design, Tooling, Quality, etc.

• Proper Lubrication, Surface Chemistry, Materials Compatibility

• Body Maker…Machine Set-up, Proper Coolant, Blow-off, etc.

• Body Maker Tooling… Design, Control, Rework, Inspection, etc.

• Washer… Set-up, Speed, Nozzle Orientation, Hold-down, etc.

• Many More

Front End Performance

1. Control the Process

2. Tooling

3. Machine Setup and Maintenance

Front End Performance Most Important Factors

80% of Front End Performance Issues are related to the following 3 Items:

Aluminum Specifications • Metallurgical specifications

• Physical specifications

o Camber, bow, etc.

• Surface roughness / profile

• Post Lube

Cupper Lube • Quality and Quantity

• Application Method

• Compatibility with Mill Oil

Soluble Oil (Die Coolant) • Temperature

• Tramp Oil %

• Quality of Filtration

Process - Materials

Cupper Lube • Application method (emulsion, neat, post-mill)

• Lube weight on cup (inside and out)

• Cupper Lube and Residual Mill Oil must be compatible

• Top coil lube (inside of cup) impacts stripping can off punch

• Bottom coil lube (outside of cup) impacts BM tooling buildup

Quality of Cup • Defects, wrinkles, pinched ears, hairs, tear-offs,

cracked flanges, etc…

• Concentric wall thickness

Process - Cupper

Transportation to Bodymaker • Avoid mechanical damage to Cup

Bodymaker Coolant • Coolant is primarily coolant, not lubrication

• Compatibility of coolant and Cupper Lube

Bodymaker Lubrication • Comes from residual Cupper lube inside/outside of cup

“Polishing” the Coolant • Magnetic filter for coolant prep prior to coolant ring

Coolant Flow • Should not wash off Cupper lube

• Coolant Presentation to Die Pack… Volume, distribution, etc.

Process - Bodymaker Transport, Lube and Coolant

Forming Reductions are Critical • Max reductions maintained in Redraw and Ironing

Ironing in Multiple Dies • Die Charts are critical

Dome Forming • Tooling for proper geometry to give proper dome strength

Process - Bodymaker Reductions and Forming

Air Blow Off • Timed Air vs. Constant Air

• Avoid hydraulic lock

• Pressure and Volume of Air

Punch Finish

Alignment

Mechanical Bodymaker

Strippers • Plastic Disposable

• Ceramic

• “Scottie Dog” Strippers

• IPS brand Bodymaker Strippers

Process - Bodymaker Stripping the Can

Large Range of Operation • Operational range > 0.006”

• No need for multiple size assemblies

Low Profile Design

Easy Assembly • Assembles in minutes

Simple Rework • Reworked at assembly level

• No dis-assembly required

Proprietary Finger / Spring Design • Reduces scratched cans and chatter marks

Trim Quality is Important • Inconsistent trim can cause problems down stream

• Avoid Step Trim

Burr on Inside of Can • Loading issues onto Deco Mandrel

Burr on Outside of Can • Crack propagation / Split flange issues

Process - Trimmer

Chemicals • Reduced chemical usage results in lower costs

• Minimize usage resulting in cost savings

• Minimizes opportunity for over etching the can

that could lead to deco loader problems

Heat / Increased Process Temperatures

Mechanical Scrubbing / Impingement • Pre-spray and recycle recovered coolant

• Proper nozzle selection and placement to optimize cleaning

• Maximize pressure throughout (Hold Down Mat / Side Support)

Process – Washer Proper Balance of 3 Essential Variables

Oven & Washer Spoilage Reduction System • Reduces tipped can spoilage

• Supports can pack throughout Washer

• Easily Adjustable

• Aligns can center-line to nozzle center

¼ Turn Washer Fittings • Reduced Costs

• Proven, Chemical-resistant Polymer

Material

Washer Process IPS Recommended Washer Arrangement

Typical Washer Setup

Washer Setup

Down Can Due to

Excess Spacing

Nozzle Spray NOT Aligned

With Can Center

Tight Can Pack

With No Down Cans

Nozzle Spray Aligned

With Can Center

Tooling Design • Optimized design / Overall design criteria

• Reductions – staying below maximums

• Specifying correct materials

• Critical Dimensions

• Critical vs. Non-Critical tolerances

• IPS has experienced tooling design staff available

Quality Supplier • Vendor relationships are important

• Turnaround times

• Reliability

• Quality and Consistency

Tooling

Tooling Inventory Management • Set up Shelving by Size

• Rework to specific size

• Retire spent tools

Inventory Tracking • Understand what is available

• Manual vs. Digital

• The IPS brand is an integrated tool tracking software

o Easy-to-Use

o Modular and Expandable

Cost Savings

• Tracking provides information to assure cost effectiveness of tools

Tooling Inventory, Tracking and Rework Theory

What to Inspect • Punch (diameters, profile / transitions)

• Die (diameters, profile)

• Historically over designed, hard to measure (Ex: Ironing Die Features)

When to Inspect • New tooling

• After Rework

• Temperature stabilization

How to Inspect • Accuracy & Repeatability

• Contact vs. Non-Contact

• Technology

• Ease of Use and SOPs

Tooling Inspection

Tooling Inspection Measuring Punch Profile

*Measured with

Punch Transition – No Use

Punch Transition – 2 Months of Use

Blend Radius Before

Blend Radius After

Tooling Inspection How Punch Profile Impacts Metal Usage

21” Monitor

Aux. Light and Magnifying Glass

Multi Use

Tool Pad

Rotary Die

Fixture

Digital Microscope

In-house rework • Dies

• Punches

Outside Vendors • Turnaround Time

• Reliability

Inventory Tracking • Where are the tools?

• What is available in house?

Inspection after Rework is Critical • Verifying size

• Verifying profile

Tooling Rework

Cleaning Aluminum Buildup • Punches and Dies

• Important to use non-abrasive methods

o IPS ToolCLEAN

• Well Suited for Necker Tooling as well

Proven Process using Ultrasonic Technology • Temperature control

• Tool specific chemical process

• Mechanical scrubbing

Punch Surface Finish Options • Cross Hatch surface finish

• Other surface finish

Tooling Cleaning and Surface Finish

Cross Hatch Overview

“Cross Hatch” is a type of Bodymaker Punch surface finish

Benefits of Cross Hatching include: • Performed in house

• Improved Stripping

• Reduced Tear Offs

Methods for applying Cross Hatch include: • Hand Cross Hatching

• Machine Cross Hatching

Types of Diamond Media include: • Diamond Stick, Stone or Paper

• Diamond IPS Proprietary Flexible Diamond Media

Performance Improvements • Example #1 – Line Performance:

• Day Before X2 Install – 1.3M Cans

• Day After X2 Install – 1.8M Cans

• Example #2 – Individual Bodymaker Performance :

• Day Before X2 Install – 14 Tear Offs

• Day After X2 Install – Zero Tear Offs

Negligible Impact to Punch Size and Profile

Precise and Consistent • Custom timed programs assure uniform finish

• Repeatable cross hatch independent of operator

Multi Language HMI User Interface

Roll Feed Adjustment • Mechanical

• Servo

Timing Adjustment • Inner Slide adjustment

• Outer Slide adjustment

• Phase angle – relationship between the two

Symptoms of Bad Timing • Wrinkled Cups

• Pinched Ears

Timed Blow Off

Machine Setup Cupper

Ram Alignment is Critical • Ram Alignment to Tool Pack

o Static Alignment – Using Indicators

o Dynamic Alignment – Software based

• Ancillary Alignment (IPS brand ))

o Cup locator, redraw sleeve, stripper

Account for Droop due to Punch

Weight • Use of Dynamic Alignment tool

Assure Wall Thickness Variation at Minimum

Avoid “Shimming of Dies” • Temporary fix, not long term solution for uniform cylinder

Machine Setup Bodymaker

Production Line Audits • Line Speed Up Programs

• Production Line Improvement Programs

• Equipment Improvement Recommendations

• Metal Substrate Conversions

• Product Quality Improvement

• Business Improvement Assessment

Can and End Line Startup Services • Installation Support

• Troubleshooting

Cost Reduction Programs • Materials, Metal and Coating

• Production Efficiency Improvements

• Spoilage Reductions

Can and End Line Integration • Customer Sponsored Approach

• Cost Effective

Operational Assistance • On-Site Staffing

• Training Programs

• QC Systems

• Store Room/Inventory Control Systems

• Tooling Control Systems

• Maintenance Programs

Product Development • Tooling Design

• Product Design

Product Specifications • Material Specification

Recommendations

• Equipment Specification Recommendations

IPS Services Offered

IPS Product Line

Special thanks to: Neil McRitchie/Conference Director

Megan Freeman/Event Manager And all of the Asia CanTech attendees

www.intpacsol.com 4010 Youngfield Street

Wheat Ridge, Colorado 80033 USA

+1 (303) 426-4881