System Plast® SpeedSet™ Solution
Publishing Date: April, 2020
Listen how System Plast® SpeedSet™ brackets saved a customer $105K in operational costs with special guest Peter Mills.
Season #: 1 Episode #: 1
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System Plast SpeedSet Solution
Carmen Ek: Welcome everyone to our PTS podcast by Regal® Power Transmission Solutions.
I'm your host, Carmen Ek. And I want to make your life a little easier by sharing customer pain points and how Regal Power Transmission Solutions is working to solve those problems. Ultimately, our goal is to help our customers' employees be successful. With me today is Peter Mills, our senior district sales manager in Indianapolis, Indiana. Hi, Peter. Thank you so much for joining me today.
Peter Mills: Carmen, it's great to be here.
Carmen Ek: Today we're going to discuss conveyor guide rail with changeovers, and how this can chew into production and maintenance time. So quick teaser before we get into the details. In the podcast today, Peter is also going to tell us about how we save the customer $105,000. But before we get into that, Peter, tell me about the industry pain point we will be discussing today.
Peter Mills: Well, Carmen, I'm glad you asked that. One common trend that we're seeing are that one conveyor line has to handle multiple package or container size. To properly convey these products, the conveyor guide rail widths need to be regularly adjusted. The problem is this can be very time consuming, require tools, and multiple personnel. It decreases available production time. This also requires you to pull maintenance staff off other tasks, and can lead to inconsistent guide rails which ultimately causes jams and loss of product.
Carmen Ek: I understand. This issue, it can be seen in beverage, in food, in personal hygiene, unit material handling plants, and places like that. Is that correct?
Peter Mills: You're 100% correct. And due to industry trends, new product introductions, and high equipment costs, plants no longer can have dedicated line per product size.
Carmen Ek: That makes sense. So let's talk about a specific example. I find that that's going to paint a better picture for our listeners. So tell us about the project that you're currently working on.
Peter Mills: Sure, the one particular place that I'm working with right now is a large beverage facility, one of the largest in the nation, if not the world. It has multiple lines within the plant, and it operates 24/7/365. One of those lines can spit out 25,000 bottles per hour, which basic math calculates out to 3.6 million bottles per day. That's pretty crazy, right?
Carmen Ek: Wow, that's amazing. And what kind of people are you working with at this facility?
Peter Mills: I'm working with process improvement engineers, line planners, and also the maintenance staff.
Carmen Ek: And what are they focused on every day?
Peter Mills: The same thing that every plant is focused on -- keeping the lines running, spitting product out, and always looking to improve their efficiencies and throughput.
Carmen Ek: That makes sense. So at this facility, what's the actual application and the problem that they're facing?
Peter Mills: They're looking at the single line directly after the pillar. The company is gearing up to introduce a new beverage, but at the same time continue production of a tried and true product on the same conveyor line. The maintenance manager actually contacted me about this opportunity, and is being proactive by installing System Plast SpeedSet brackets to give him speed and flexibility for his line changeovers. This will minimize downtime when the new product comes on line.
Carmen Ek: That's smart to think ahead like that. So for those of you who aren't familiar with System Plast SpeedSet brackets, this is a very quick and easy way to consistently and repeatedly adjust the width of the conveyor line. The SpeedSet brackets are spring loaded, and they require no tools to make an adjustment. So Peter, this isn't the first time that this plant has used SpeedSet brackets. Is that correct?
Peter Mills: You are 100% correct. As I mentioned earlier, he contacted me this time because he's had such great success in the past. The first go around was on a line right after the labeler, where the changeovers were extremely frequent. Here, we were able to install approximately 60 SpeedSet brackets, and the documented cost savings was directly $105,000.
Carmen Ek: Wow, $105,000. That's a huge savings. Where did the savings primarily come from?
Peter Mills: Well, we ultimately came to that figure by calculations based on increased up time due to time savings. The staff was able to change guide rail dimensions faster, which meant they could fire up the production line that much quicker. Previous changeovers took roughly two hours. Once the SpeedSet brackets were installed, the changeovers took 30 minutes. With this, we were able to give the plant one and a half hours per week of increased production -- one and a half times 52, you do the math. And when they're spitting out 25,000 bottles per hour, that adds up extremely quick.
Carmen Ek: That's a great story. I want to let everyone know, SpeedSets aren't always a silver bullet. There are constraints when it comes to the number of changeovers or the max allowable difference between the largest and the smallest containers. And then you also really want to have a Regal sales manager like Peter, or an application engineer to help you select the proper bundle of parts. We also insist that are perceptive technology team does the onsite installations. There's some tricky areas, and an install that goes wrong -- it's not going to save our customer time. We've seen this happen to others who have tried to install it on their own and it just didn't work out. So we really like to have are perceptive technology teams do that installation.
Peter Mills: Yes. Definitely get myself or one of my colleagues involved to help you out.
Carmen Ek: So we're going to wrap up here, Peter. What else would you like to add?
Peter Mills: Well, the one big takeaway that I want our listeners to get from this is -- we are selling a product, but in all reality, we're not, we're selling a plant production facility more time.
Carmen Ek: Ah, more time. We could all use more of that, couldn't we? Thank you, Peter, for your time today to tell the story so others can benefit from this solution. I really appreciate it.