The Value of Maintenance and System Analysis

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The Value of Maintenance and System Analysis

When a packaging line shuts down, it is time and production lost forever. Most companies today have regularly scheduled maintenance programs and some have packaging line system analysis, but few seem to have combined the two concepts.

Having back up replacement parts, especially in today’s servo-controlled environment is essential to shorten unplanned downtime. The “bigger picture” suggests that utilizing a system that collects and analyzes data from the entire production line can pinpoint where major stops originate, calculate the individual category of downtime (changeovers, lunch breaks, breakdowns, jams, etc.) and identify where preventative maintenance is best utilized, would result in significant cost savings.

An example of this process in action is on a packaging line where multiple pieces of equipment operate in line to wrap, insert, weigh and case pack a product. The case packing did not operate even close to capacity and system analysis discovered the bottleneck was back at the insertion stage caused by jamming. Planned maintenance was scheduled at this station with higher frequency and focus on continuous adjustment monitoring by the operator. The result was an increase in overall output of 9%.

The old time mentality of “run it till it breaks” does not fly in today’s world of sophisticated high efficiency production systems. Combining the tried and true process of monitoring, cleaning and adjusting equipment with computer evaluation of overall system equipment efficiency and identifying negative factors in production, makes sense for an increasing number of companies today.

Article Source: http://articlenexus.com

George Van Lieu is a manager for Belcorp, Inc., an automated packaging equipment supplier located in Cincinnati, Ohio.

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