Sanford sold on 'cell' concept (sidebar)

Automating Sanford’s Sharpie® packaging line was the first step, but according to plant manager T.J. Jordan, there is much still to be done. “We need to improve changeover designs,” he explains, noting that it currently takes six hours to change the line over from 1/card to 2/card format. “Even though one- and two-marker packs take the same size blister and card, the alignment of the markers isn’t the same,” Jordan explains. “We end up having to switch the trays, blisters, cards . . . everything when we change over.” Additionally, the approximately 100 flights built into the conveyor that transports blister packs from the heat sealer to the collator all must be removed and replaced by hand every time the line is changed. But help is on the way—Jordan says the company is working with suppliers Alloyd and PMI Cartoning on a plan that will reduce the changeover time to between one and two hours. One solution being investigated, according to Jordan, is the replacement of current conveyor flights with ones that incorporate a smaller-sized flight that can be easily snapped into a larger flight when Sanford wants to run 2/card packs. Speedy changeover has already proven to be a benefit of the new cartoning and case packing equipment on the Sharpie line. “We used to have to adjust everything with screws,” Jordan says. Now, however, tool-less changeover is accomplished on the back portion of the line in just 30 minutes.