Magazine

Erection
chamber
Sealing
station
Folding
chamber
Transfer
mechanism
A REDESIGN METHODOLOGY FOR ANALYZING AND IMPROVING THE
PERFORMANCE CAPABILITY OF PACKAGING MACHINERY
Introduction
A two-year research project has been undertaken to support the
development of a redesign methodology which both complements and
enhances the traditional design process of the packaging industry. This is
achieved through the interchange of knowledge and design theory between
the technical partners and industry as well as the application of
computational modelling and analysis techniques.
The redesign methodology builds on the practical experience of the
companys design team and provides an analysis strategy to support
development. This is based upon fundamental principles that can be
employed to evaluate the limitations of an existing design, establish the
potential for improving the design and, if necessary, the approach can be
adopted in establishing a new design. In particular what emerges are three
levels of response by way of redesign. These represent: incremental,
elemental and radical changes. Each of these is described and validated
by way of three industrial case studies, which illustrate the various levels of
redesign response.
The individual tasks and activities of the redesign
methodology
Current Machine
Machine Tests Discussion and Review
Performance Capabilities of Machine
Experimental Investigation
Analysis
Comparative Study and Assessment
Evaluation and Recommendation
Redesigned Machine
Modelling
Radical Change Elemental Redesign Incremental Change
Factors Limiting Performance
Detailed Design
M
a
c
h
in
e

E
v
a
lu
a
t
io
n

D
e
v
e
lo
p
m
e
n
t

o
f

a

R
e
d
e
s
ig
n

S
t
r
a
t
e
g
y

A
n
a
ly
s
is

a
n
d

I
n
v
e
s
t
ig
a
t
io
n

A
c
t
i
v
i
t
i
e
s

o
f

t
h
e

m
e
t
h
o
d
o
l
o
g
y


Incremental redesign
Initial redesign studies concentrated on seeking performance improvements
within the existing design envelope. This essentially involves the re-
specification of core components. In one case study the current
performance of the case erector was lagging that of competitors and
excessive vibrations were occurring at higher operational speeds.
Benchmark tests and an evaluation of new technologies for pneumatic
component, identified that considerable improvements could be achieved
through the introduction of alternative component types into the existing
design. By respecifying pneumatic cylinders and shock absorbers,
vibration was attenuated and a substantial increase in production capability
was realized.
A kinematic model of a
case erector
incorporating incremental
changes
Elemental redesign
In other cases, where major improvements could not be made without
undertaking the redesign of certain components and sub-systems the
elements limiting the machine performance were identified. Design efforts
were then directed to the creation and development of alternative devices
and approaches that would better satisfy new design goals. In discussion
with the company, these were refined and compared until a feasible
redesign strategy evolved. These changes were then integrated with the
existing machine and the performance assessed. Through such an
approach a range of elemental redesigns can be generated which when
combined significantly improve the performance of an existing design,
whilst retaining the majority of the fundamental principles.
Radical redesign
Finally, there is a category of case studies in which the investigation led to
the conclusion that major improvements in performance could only be
achieved through equally major changes in the operating principles.
During the creation of such designs new operating principles and
processes as well as those which are best practice within the industry are
considered. Throughout this development, designs were formulated to
build upon the skills, experience and strengths of the company as well as
considering new technology and techniques. Such an approach has
culminated in new geometric configurations and modular layouts of
machines, as well as the generation of independently driven and controlled
actions and processes
Existing configuration of an overwrapper
Elemental redesign and optimisation of an overwrapper
Existing design for a carton
erector
Radical redesign solution
for a carton erector
http://people.bath.ac.uk/ensgm/redesign.pdf