The main point
A complete line is more than several fast machines. Each station must receive and release products predictably, communicate faults and recover without damaging packs or confusing product tracking.
Packaging Lines
See the machinery and application options most closely matched to this production question.
1. Map the process
Draw every step from empty pack or raw product to finished case. This should be recorded in the customer requirement so it can be tested rather than assumed.
- Draw every step from empty pack or raw product to finished case
- Show manual work, inspections, rejects and rework
- Record current cycle and waiting time
2. Set one line target
Use sustained good output. This should be recorded in the customer requirement so it can be tested rather than assumed.
- Use sustained good output
- Create a product-and-pack matrix
- Define changeover, cleaning and availability assumptions
3. Design product flow
Match conveyor heights and directions. This should be recorded in the customer requirement so it can be tested rather than assumed.
- Match conveyor heights and directions
- Add accumulation where normal micro-stops occur
- Control unstable packs through transfers and machine entries
4. Agree controls and acceptance
Define start, stop, blocked, starved and fault handshakes. This should be recorded in the customer requirement so it can be tested rather than assumed.
- Define start, stop, blocked, starved and fault handshakes
- Coordinate guarding and operator access
- Test every station and the complete line under representative load
Customer comparison table
| Line element | Customer decision |
|---|---|
| Rate | Sustained good packs per hour |
| Buffer | Where and how much accumulation is required |
| Control | Who owns line start, stop and fault recovery |
| Quality | Where defects are detected and rejected |
| Changeover | How the full line moves between formats |
Relevant Lancing routes
Use the guide to prepare the requirement, then continue to the specialist routes below.