When Integration Is Part Of The Solution
Yesterday we shipped a classic example of an Integration Project. Our customer is filling popcorn into PET bottles, which are then Capped, Induction Sealed, Bottom Coded and Labeled. After the installation of the above mentioned equipment, plans are underway to also add a Bottle Unscrambler to automatically orient and place containers on the conveyor at the beginning of the line.
The "mix" of products on this particular line include machinery from other suppliers (OEM) and Liquid Packaging Solutions (LPS):
- Auger Filler to fill the popcorn into the bottle (OEM)
- Check Weigher with Rejection System (OEM)
- Automatic Capper with Sorting Elevator (LPS)
- Bottom Coder (OEM)
- Bottom Coder Transfer Station (LPS)
- Wrap Labeler (OEM)
- Conveyors (LPS)
- Integration Services (LPS)
- Installation Services (LPS)
One of the most critical challenges was the layout of the complete line to ensure that it fits into the customer's existing space. LPS took the lead on this issue by communicating and coordinating with the other OEM suppliers to get accurate drawings of each piece of equipment, and folding them into the overall line layout. Since LPS provided most of the conveyors for this project, and conveyors really define the layout, this only makes sense. Several revisions of the drawing were circulated back and forth between our customer and us to ensure that the final layout would fit in the tight space in the customer's plant. Our ability to generate an accurate Line Layout including the machines we manufacture here in addition to the machines provided by the OEM supliers is a Value Add for our Customer.
Another way in which we added value to this project was to coordinate the purchase and delivery of each of the OEM machines. This approach afforded our customer the convenience of dealing with fewer financial transactions. Additionally, they only had to worry about one "delivery date" - ours. We took care of making sure that the other machines arrived in our plant in time to achieve the desired delivery date.
When all of the machinery was either built or delivered to our facility, we then performed yet another value add. We put the line together in our shop so that we could test all of the machines as a complete system. Having the machinery staged here in our plant is the best place to perform the "shakedown cruise", so to speak. Performing this work affords us the ability to make modifications and changes as needed before the machinery gets to the customer's plant. "Debugging" machinery is always a part of the process and it is far better to do it here than it is to debug a line in the customer's plant.
Having the capability to "stage" the line in our plant also gave our customer the opportunity to visit us and sign off on the machinery before shipment.
After signoff by the customer, we then disassembled and prepared all of the machinery for shipment, and then loaded it all on the truck. One shipment was made instead of multiple shipments from multiple locations. Efficient.
Finally, one of our Technicians will travel to our customer's plant and install the line. With all of the professional and competent project managment work which went into this project, we're confident that the installation will go well and that our customer will be very satisfied.
Integration of a liquid packaging line is always detail intensive, just as building an individual machine is detail intensive. Liquid Packaging Solutions understands always that the devil in the details and is well suited to manage them so that our customers don't have to.
If you have a project which requires our Integration Services, we hope that you'll contact us to discuss it. We will ensure that you are glad that you did!
Posted: December 9, 2009
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