A large German company in the food industry commissioned the interim manager to develop an automated, reliable filling process for a packaging machine. Previously, the cartoning machine used in this process had been loaded by 2 employees at 2 manual filling stations. This work is very monotonous. It is also not very efficient and comparatively expensive.
Specifications and systematic structure of the system developed
After the interim manager had clarified the customer's expectations in numerous discussions, he drew up specifications and developed the systematic structure of the system. He organized the project according to the waterfall model.
The system developed by the interim manager consists of a bunker, ascending conveyor and feed system with camera guidance of a robot. The customer also equipped the mobile cartoning machine with a filling hopper. A sensor system ensures stable filling speeds and compliance with safety requirements. The interim manager also developed a vacuum gripper, which was manufactured using 3D printing (SLS technology).
Cycle times for filling reduced to a third and processes automated
The requirements for the new design in terms of cycle time, space requirements, size of the hopper and hygienic filling design were clear. The interim manager set the cycle time in such a way that the packaging time was reduced to a third. In terms of space requirements, the system had to be as small as possible. As the system works with food, strict hygiene regulations of the food industry had to be adhered to as well as GMP guidelines (Good Manufacturing Practice).
New requirements of the client were quickly implemented using 3D models
The interim manager already exchanged ideas intensively with the client during the design phase using 3D models. This meant that special requirements for facilitating cleaning processes, for example, could be implemented quickly.
During the design phase, however, the client decided on a smaller model of the cartoning machine. As a result, individual elements such as a coupling or the alignment of the filling material (tubes) had to be adapted. The interim manager overcame these challenges by rescheduling and developing new 3D printed parts.
Robot-assisted new system runs stably - and significantly more efficiently than the old process
The model was then approved, the system manufactured, tested and put into operation. The customer is satisfied: The system runs stably and reliably. The fast robot, the pneumatics used and the lightweight, newly developed vacuum gripper were able to increase the filling speed. Refilling takes place without interrupting the operation of the system.
The employees no longer have to fill the bunker manually, but only every 2 hours.
The clear communication of the interim manager and his openness to the exchange of ideas also ensured that the client's expectations were met.
