Tech Fest 2013 (Costa Rica)

Abstract Submittal Form

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Introduction/Backgr
ound
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Method
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Mega Pack Line Vip Project

Poster
Tech Report
Daniel Calvo Camacho
Jairo Barrantes
The Mega Pack VIP Project is intended to implement a more efficient
packaging line in the Super Stiff, integrating the sub assembly operati
of Hooping, Packaging and Boxing areas plus the installation and
validation of an automated Pouch Sealer.
The area of hooping, packaging, sealing and boxing of Amplatz Super
Stiff were detected subject to improvement in terms of efficiency since
there were found idel times during production due to following a Kan
Ban production flow, excess of labor executing non-value added
activities and long cycle times.
The methodology was the following:
1) Integration of the different operations (Hooping, Packaging, Sealing
and Boxing) was analyzed based on a simulation, setting the expected
production output and cycles times in order to implement the project.
2) Since an automated band sealer was installed as part of the
production line integration, a full process characterization (Tech Report
90826005) was executed in order to guaranty that the sealing process
is capable and meets specification. Preliminay results obtained from
the FAT were analized, then a DOE and a Confirmation Run were
executed in order to release the process for validation. One of the main
goals of this activity was to confirm one single operational process
range for the two types of pouches currently used and avoid re-setting
of the equipment during production orders changes.

Results
(4000 Char. max.)

1) As part of the production line integration, the main results are the
following:
1.1)
1.2)
1.3)
1.4)

51% reduction on product transportation.

Idle space increase in 711 sqft.
7 direct labor reports were moved to other areas.
Estimate savings up to 88.1k US$.

2) In regards of the process characterization, the main results are the

following:
2.1) Results from FAT were key inputs in order to have an
optimization DOE and being able to set the optimum process ranges by
a contour analysis.
2.2) One single operational range was identified to operate the
equipment for the two types of pouches, eliminating potential down
times because of setting parameters.
2.3) The process validation executed as per report 90825998 were

concluded as satisfactory and the sealing process was released for

production purposes.
Conclusions
(1000 Char. max.)

Mega Pack Project was an integrated VIP that let to implement a new
production line concept and implement a new piece of equipment that
provided results in different areas, such as:
1) Efficiency increase.
2) Reduction of non-added value activities: transportation
reductions.
3) Reduction of labor.
4) Savings in terms of efficiency improvement
5) Successful characterization and validation of the sealing process
following results obtained from FAT, execution of a DOE and capability
analysis during validation.