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Send to KindleStrapping gets an upgrade at Ford
To activate the strapping mechanism the operator can either step on a foot pedal or press a button and the PP strap automatically wraps itself once around the package. An external tension control switch lets the operator regulate the tension to the correct level as determined by the material used and the part type. As soon as the band reaches that preset level of tension heat-sealing and cutting are automatically activated.
According to Lucaire the corrugated specifications vary considerably from one part to another. Virtually everything from 200#-test single-wall to 500#-test triple-wall is used. The band tension needed to effect a secure closure varies from one box to another. With its former equipment Ford couldn't adjust the tension without a mechanic making an internal adjustment. To avoid this downtime workers set the band tension at a midpoint for all packages. Thus some banding was too loose and some too tight.
With its ability to regulate tension according to the part and box material encountered the new machine eliminates at least one damaged part per week per distribution center served. This in turn results in significant savings by eliminating rework repair reordering and/or transportation. It's also making the PRC a hero at Ford parts distribution centers all over the world.
More benefits
Additional benefits now enjoyed by PRC since the strappers were installed include these:
*Energy. While the old strappers' motors ran constantly the Ovalstrapping machines run only on demand. According to Lucaire's estimates a typical part requires three bands taking 7.5 seconds of motor time. He estimates an energy savings of $1.38/machine/day because the new machine's motors run only on demand.
*Speed. Cycle time on the new machines is 0.5 seconds faster than on the machines that have been replaced.
*Waste. The new machines cause little or no wasted strapping material.
*Maintenance. All functions are controlled by a single belt-driven cam. An interior diagnostic panel shows if an area of the machine needs attention eliminating time-consuming tear-down and inspection. Also heater and cutter bars can be replaced without the use of tools and in less than one minute.
Ford declines to quantify the dollars saved since the new strappers were installed. But Lucaire figured on a two-year payback on the investment when he presented top management with his cost justification figures prior to the machines' installation.
He's quick to point out however that as important as cost savings was it wasn't the only motivation behind the project.
"Each machine provides a high-quality uniformly secured packaged part" he concludes. When the firm's motto is "Where quality is job one" what could be more appropriate?
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