PETpla.net Insider 04 / 2010

PREFORM PRODUCTION 25 PET planet insider Vol. 11 No. 04/10 www.petpla.net Manufacturing Advisory Services – PET case study The Husky Manufacturing Advisory Services team provides operational consulting, design and project management services to help customers increase the operating efficiency of their plastic injection moulding facilities. A case study explains how Husky worked with a PET cus- tomer to improve the overall operating efficiency of their operation. The customer is a PET preform manufacturer in Europe with eleven injection moulding machines for water, CSD and edible oil preforms. The situation The Husky Manufacturing Advi- sory Services team has worked with this manufacturer since 2003, performing yearly plant audits of the entire operation, identifying, quantify- ing, prioritising and following up on the implementation of improvement opportunities. Flexible maintenance and asset management software solutions Husky Injection Molding Systems has launched two soft- ware packages as part of its services offerings. Pro-Act is described as a flexible maintenance program; Shotscope NX is an integrated process and production monitoring system. The company says that the Pro-Act maintenance program is based on a proactive maintenance model. It is intended to maintain high performance and to avoid system degrada- tion by using monitoring and measurable results to pre-plan and customise maintenance schedules, and to identify and respond to issues before they become problems. The program offers three levels of service, from entry-level to advanced. Shotscope NX is presented by Husky as an integrated process and production monitoring system that provides expe- dited information to help manufacturers control processes and improve productivity while minimizing scrap and downtime. The software is designed to help manufacturers characterise and report on production and process statistics at both the dis- crete systems and plant-wide levels. The company says that Shotscope’s real-time monitoring and analysis helps manu- facturers simplify reporting, improve data flow and coordinate more efficient plant scheduling. Additions over the previous Shotscope system include an enhanced user interface. The software is web-based, which allows access from anywhere and at any time. It is compat- ible with any brand of equipment and able to connect with both PDA and webcam. www.husky.ca 15% reduction in energy consumption (in kwh) since 2003, through: Migrating to the latest drying and  chilled water technology Improvements to plant HVAC sys-  tems Increase in machine efficiency.  8.3% conversion cost reduction between 2008 and 2009 (excluding materials), as a result of: 10% reduction in maintenance and  repair costs 7% reduction in labour costs.  Average payback for projects imple- mented approximately 1.2 years. SPHERO® underwater pelletizers ... … refreshingly different Automatik – Your system supplier for all pellet shapes. If you want more than the usual, contact us. www.automatikgroup.com Please visit our Open House June 11, 2010 Key results OEE (Overall Equipment Effective- ness) has improved from 81.9% in 2003 to 91.2% in 2009. Key areas of improvement include: Implementation of a Total Pro-  ductive Maintenance program 7% - 10% cycle time improve-  ments through the implementa- tion of a process optimisation program and process monitoring software Process standardisation resulting  in reduction of scrap material. C O S T EFFICIENCY ENERGY EFFICIENCY