Case study, May 2016: customers saves € 90.000,-- annually
A Hoppmann client assembles special spray caps manually onto filled aerosols cans.
Before: Operators place the rigid plastic spray caps manually, achieving at best 1 every 4 seconds, so the output is 15 cans a minute (= 900 cans per hour = 7.200 per shift). Average batch sizes are 42.000 pcs, annual quantity +/- 500.000 cans. For this type of product there is limited space for storage of filled cans (hazardous goods), short lead times are a must, so the assembly of the spray cap require the use of multiple operators (average 3 persons). Calculating with minimum wages for an average worker of € 30.000,- per year, total wages for this type of production is € 90.000,-. Apart from this, there is a high potential risk for physical injuries to hands, pulses and arms, even with the use of dedicated tools. Also the risk of product emission during assembly is considerable, leading to higher emission of green house gases.
Solution: Client decided to invest in a Hoppmann feeding and assembly solution, to be placed in an area close to the filling line. Cans are either placed manually onto an unscrambling table or via a conveyor track, taking them automatically from the production line. From the unscrambling table they are transported onto an automatic conveyor. The spray caps are fed in bulk in the Hoppmann prefeeder, which feeds them in a gentle way to the Hoppmann feeder. In the feeder the spray caps are singulated and orientated and then exit one-by-one onto an exit conveyor. From here they are led to the continuously rotating assembly turret, where the spray caps are positioned and placed in a safe and orderly way onto the aerosol valve, without causing any emission of gas and product.
After:Spray caps are placed automatically at a speed of 80 pcs/minute (= 4.800 cans per hour = 38.400 cans per shift). Assembly output has increased by 430%. Production time is reduced from 6 days to just above 1. Lead time reduction is 1-1,5 weeks. Risk of physical injuries has been reduced to zero. Quality of production has increased, by reducing emission of propellant and product, which means reducing emission cost and a reduction of the companies carbon foot print.
Result: by investing in a Hoppmann® automatic feeding and assembly solution, client gained more than just increased output. And just as important, the return-on-investment of this project was less than 1,5 years.MORE HOPPMANN TECHNOLOGY