With the economy still struggling to recover from the COVID-19 outbreak, companies are looking for ways to optimize processes and cut costs. Packaging lines have been a target for improvements over the past few years, so it is no surprise that they continue to lead today's list of top areas for improvement. Here are five tips that can help guide facility managers along their way to packaging line optimization.
The effectiveness of a packaging line is measured by the speed at which it can move products out of an assembly workstation and into a shipping container. Any slowdowns along this process not only decrease output but also lead to increased labor costs. In many cases, facilities management teams have found that when just one area of a packaging line slows down—whether it be cartons, labeling machines, or sealing equipment—the entire production process begins to suffer.
When managers identify opportunities for improvement on their packaging lines, they should look at both the immediate concerns within one department as well as how changes will impact other parts of the line. Line optimization requires coordination between multiple departments and continuous communication with production staff to ensure all parties are aware of possible disruptions and delays.
With the goal of improving packaging line performance and efficiency, here are five tips managers can use to optimize their packaging process.
The benefits of an optimized packaging line extend far beyond the final product.
To improve your current productivity, you should consider the following options:
If you are making changes across your entire packaging line, it's important to know what needs to be improved. Creating a list of problem spots or bottlenecks will help ensure that the optimization process does not overlook any areas for improvement.
One way to find problem spots quickly is by looking at the details surrounding past errors on the packaging line. Identifying errors experienced by employees can help managers identify common mistakes and develop workarounds.
For instance, if one employee is frequently struggling with a specific labeling machine, they may need additional training or an adjustment to their schedule so they can receive assistance from another colleague.
You should determine how many different types of packaging machines are necessary for effective production before installing them on your packaging line.
For example, do you have enough space inside your warehouse to accommodate all that equipment? What is the precise sequence in which they will be used? How much maintenance will they require? With this information, you can establish an ideal layout for each piece of equipment before installation.
Consider the use of multiple case erectors, cartoners, and shrink-wrappers because they can handle different types of packaging materials better than one machine can. This also helps to minimize downtime due to maintenance issues.
Moreover, if you need a cartoner that can handle light-duty items in addition to heavy-duty packages, using two systems might be more beneficial than choosing a heavier-duty model that only works on one type of product.
Today's cartoners can handle a variety of different carton sizes and weights. To maximize your packaging line, you should design it to accommodate as many different products as possible.
For example, one cartoning machine can be configured to package both soup and beans using the same equipment—saving time and money. A cartoner that produces multiple cartons at once is also efficient because it operates on fewer machines, which reduces maintenance costs and minimizes downtime.
Cartoning machinery can run square or rectangular cases just as easily as round bottles or cans —another way to maximize the capacity of your packaging line without adding additional equipment.
The more efficiently cartoning machinery packages products, the less likely it is to produce scrap materials. Many machines have built-in features that preserve the integrity of the packaging material to ensure its recyclability or reuse, which also reduces overall costs.
For example, cartoners can be equipped with sensors that help detect incorrect path orientation between cartons and trays so products are packed securely without being wasted. A trolley system can be configured for automated tray loading on a cartoner to reduce operator fatigue while increasing productivity—thereby minimizing mistakes.
Additionally, some cartoning equipment enables line operators to select different package sizes at the push of a button, rather than having to load different size cases or trays manually. Doing so allows one cartoning machine to produce multiple sizes of cartons without having to change the size of the case.
Because cartoners are extremely reliable, one of the best ways to maximize your packaging line's efficiency is to prevent downtime whenever possible. Once downtime occurs on a packaging machine, it takes time and labor to fix—increasing labor costs and decreasing productivity.
For example, installing an oil drip pan near the input area of a cartoner can help prevent downtime by keeping oil spills contained so they don't cause damage to other parts of the machinery. Another way to avoid downtime is by storing replacement parts easily accessible for quick repairs.
If you're looking for packaging equipment that can be customized based on what you need, contact BluePrint Automation today. We provide new & used cartoning machinery for sale, as well as precision-built machines for use in a variety of applications.
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