HS Labelers – Downtime Results

Shane Ireland

University of Pittsburgh ’14

Industrial Engineering

Continuous Improvement Co-op

Overview

• Recorded Downtime for 8 complete shifts

– 7 on 1st shift, 1 on 2nd shift, Duration (4/2-4/11)

• Categorized all the different steps for why the machine was down:

Idle Time

Changeover

Preventative Cleaning

Jam-Ups

Mechanical

Operator Adjustment

• Took the average for the 8 shifts

7 hour 6 min

HS Labeler Opportunity Map

Run Production, 426.52

Preventative Cleaning, 23.50

Changeover, 14.49

Idle, 6.74 Jam-Up, 4.54Mechanical,

2.53

Performance

Observed Average Stick Count: 275,300

Average Stick Count on all shifts from 4/2 – 4/11: 247,500

Difference:=

275,300 - 247,500 = 27,800 Sticks!

27,800 / 644 = 43.16 Less minutes of Downtime

Top 13 Reasons For DowntimeReason Sum of Time Frequency Average Time/Shift Downtime % Adjusted Time/Shift

Reheat Heater 81.75 128 0.64 10.22 19.11% 18.47Daily PreventativeCleaning 69.03 8 8.63 8.63 16.14% 15.59

Label Roll Change 46.88 71 0.66 5.86 10.96% 10.59

Remove Roller Wraps 31.00 24 1.29 3.88 7.25% 7.00

BH Crayon Level too Low 22.62 26 0.87 2.83 5.29% 5.11

Wait on Molder 18.38 7 2.63 2.30 4.30% 4.15

Clean Return Screen 17.52 1 17.52 2.19 4.09% 3.96

Clean Cutter 16.72 36 0.46 2.09 3.91% 3.78

End of Shift 16.57 3 5.52 2.07 3.87% 3.74

Clay Loader Malfunction 14.95 1 14.95 1.87 3.49% 3.38

Color Change 14.40 2 7.20 1.80 3.37% 3.25

Communication Error 8.87 5 1.77 1.11 2.07% 2.00

Boxed Crayons 8.45 31 0.27 1.06 1.98% 1.91

1)2)3)4)5)6)7)8)9)10)11)12)13)

Preventative Cleaning Breakdown

Daily Preventative

Cleaning, 8.63

Remove Roller Wraps, 3.88

Reheat Heater, 2.43

Clean Return Screen, 2.19

Clean Cutter, 2.09

Preventative Cleaning Per Shift - 24.59

15.59 min

7.00 min

3.78 min

Idle Breakdown

End of Shift, 2.07

Communication Error, 1.11

Boxed Crayons, 1.06

BH Crayon Level too Low, 1.02

Reheat Heater, 0.61

Empty Rejected Crayons, 0.40

Idle Downtime Per Shift - 6.74 min

Average: 5.52

minutes

Frequency: 3

3.74 min

2.00 min

1.91 min

1.84 min

.72 min

Why Does This Matter

• What does 1 minute of downtime represent.

– 650 * 6 = 3,900 Crayons per Shift

– 3,900 * 3 = 11,700 Crayons per Day

– 11,700 * 5 = 58,500 Crayons per Week

– 58,500 * 52 = 3,042,000 Crayons per Year!

–3,042,000 * 43 =

130,806,000 Crayons per Year!!!!

What Makes a Productive Labeler?

Troubleshooting problems quickly and effectively

Pay attention to their surroundings

Anticipate Downtime

• Label Roll Changes

• Daily Preventative Cleaning

• Main Hopper Level too Low

3) Label Roll Changes (5.86 min/shift)

Average: 39 seconds, approx. 9 per shift

Be Prepared!!! Things you can do prior to Roll Change:

• Have Splices

Ready

• Pre-cut the next

roll

• Clear your run off

3) Label Roll Changes (cont.)

Be in Position when the roll runs out.

•Make a nice clean

cut

•Make sure the splice

is secure

Preventative Cleaning?

A clean machine is a happy machine

• Remove Roller Wraps – Check before every Label Roll Change

• Clean Cutter – At least every other Label Roll Change

3) Label Roll Changes (cont.)

Restart the Labeler right away!!

• Reheat Heater (Average: 38s)

• Great Opportunity to:

1)Box Crayons

2)Remove old Label Roll

3)Put new Roll on the wheel

4) Remove roller Wraps (3.88 min/shift)

Use your best judgment

If possible perform while the machine is already down• Main Hopper Crayon Level too Low

• Label Roll Change

• Color Change

One roller wrap leads to a Few roller wraps which

leads to MANY roller wraps

5) Main Hopper Crayon Level too Low (2.83 min/shift)

3 Causes

1. Smashing and Missing Crayons in the In-feed Hopper

2. Labeler Speed exceeds Mold speed by too much

3. Restart Machine while Back Hopper is too low

• Wait for the Main Hopper to fill half way.

• Exception to the Rule:

• 10 minutes of label left on the roll

2) Daily Preventative Cleaning (8.63 min/shift)

Performed with the first hour of each shift

• Floater should always be available to help

• Makes YOU responsible for how well your labeler will run!!

• Eliminate End of Shift Idle time

Daily Preventative Cleaning (cont.)

Things you can do prior to the Daily Preventative Cleaning:

• Empty Rejected

Crayons

• Empty Water Pan • Clean Crayon Run

Daily Preventative Cleaning (cont.)

Communication is key!!!• Floater initiates the daily cleaning

• Let the Molder know you are ready to start

• Communication Error

• Operator shouldn’t have to wait for the molder or vice versa

• Sync all three processes to eliminate unnecessary idle time

Daily Preventative Cleaning (cont.)

Molder should start cleaning once the robot stops dropping crayons

Operator starts cleaning theIn-Feed Hopper once the last crayon transfers to the Main Hopper

Operator Cleans the guard and scrape the built up residue off of the hopper

Daily Preventative Cleaning (cont.)

Don’t let the main hopper run all the way out!

Manually place remaining crayons in a box

Daily Preventative Cleaning (cont.)

Operator places the Two Wheels and Main Hopper Guard on the desk for the Floater to clean

Operator-scrapes Hoppers, Floater-Cleans the Wheels

Daily Preventative Cleaning (cont.)

• After reassembling the Hoppers, Replace the Crayons

• Communicate to the Molder that the Hoppers are ready to be filled

Daily Preventative Cleaning (cont.)

• Operator can go check the filter

• Floater should be finishing up the inside

Conclusion

Minutes matter and seconds add up

Anticipation and Preparation is the easiest way to a successful shift

You truly are the X – factor.

Thanks for listening!

What Now?

• Preventative Cleaning will be performed within the 1st hour.

• Floater will initiate the cleaning

• Communicate to the molder the start of the process

• Follow Preventative Cleaning Procedures

• Anticipate your label roll changes

• Be Prepared!!

Any Questions?