End Manufacturing at Rocky Mountain Metal Container, with views on emerging technology

End Manufacturing at Rocky End Manufacturing at Rocky Mountain Metal Container, with Mountain Metal Container, with views on emerging technologyviews on emerging technology

Paul SchrockMillerCoors LLC

Rocky Mountain District MBAA Technical Meeting

9/20/2008

What is an End?What is an End? Ends Come in a variety of Sizes and Ends Come in a variety of Sizes and

Variations but all are an integral Variations but all are an integral component of the 2 Piece Aluminum Can. component of the 2 Piece Aluminum Can.

The End is seamed on the top of the can The End is seamed on the top of the can and forms the beverage consumption and forms the beverage consumption point.point.

Raw MaterialsRaw Materials There are 2 main Direct Raw There are 2 main Direct Raw

Materials associated with End Materials associated with End ManufacturingManufacturing AluminumAluminum Liquid LatexLiquid Latex

AluminumAluminum The Aluminum comes in 2 FormsThe Aluminum comes in 2 Forms

Shell Coil (End Stock)Shell Coil (End Stock) Tab Coil (Tab Stock)Tab Coil (Tab Stock)

LatexLatex Latex or Compound is placed in Latex or Compound is placed in

the curl of the shell as it cures it the curl of the shell as it cures it becomes the gasket as the end becomes the gasket as the end is seamed to the filled can.is seamed to the filled can.

Raw Material UsageRaw Material Usage

Use ~ 1 Million lbs of Aluminum / Use ~ 1 Million lbs of Aluminum / WeekWeek

Use ~ 86 Gallons of Latex / WeekUse ~ 86 Gallons of Latex / Week

End Manufacturing ProcessEnd Manufacturing Process

Main processes to produce an EndMain processes to produce an End

Blank and Curl the ShellBlank and Curl the Shell Line the CurlLine the Curl Convert the EndConvert the End

Shell Press and CurlersShell Press and Curlers

Shell Press Coil In FeedShell Press Coil In Feed

Manufacturing Process - Blank the Manufacturing Process - Blank the ShellShell

Shell PressShell Press

Manufacturing Process - Blank the Manufacturing Process - Blank the ShellShell

Single Stroke, Pneumatic Assist Single Stroke, Pneumatic Assist Forming DieForming Die

Manufacturing Process - Blank the Manufacturing Process - Blank the ShellShell

CurlerCurler

Manufacturing Operation - Curl the ShellManufacturing Operation - Curl the Shell

Curled Curled ShellShell

Work In Process / Machine Work In Process / Machine InfoInfo

Shell Press / Curler Info

•7 Shell Presses at RMMC•Press Strokes at 560 SPM•2800 EPM, 4,032,000 EPD•Each Consumes ~ 750 LBS Aluminum / HR

Stick FeedsStick Feeds

Material Material HandlingHandling

Traffic CopTraffic Cop

Material Material HandlingHandling

Six head Rotary LinerSix head Rotary Liner

Manufacturing Process – Line the CurlManufacturing Process – Line the Curl

Compound DryerCompound Dryer

Manufacturing Process – Line the CurlManufacturing Process – Line the Curl

Lined Lined ShellShell

Manufacturing Process – Line the CurlManufacturing Process – Line the Curl

Liner Info•14 Liners at RMMC•Liner Runs 1480 RPM•3 Turns of Lining

BalancerBalancer

Material Material HandlingHandling

Conversion PressConversion Press

Tab Stock In feedTab Stock In feed

Manufacturing Process – Convert the Manufacturing Process – Convert the EndEnd

Form TabForm Tab

Manufacturing Process – Convert the Manufacturing Process – Convert the EndEnd

Form ShellForm Shell

Manufacturing Process – Convert the Manufacturing Process – Convert the EndEnd

Form Shell - ProgressionForm Shell - Progression

Manufacturing Process – Convert the Manufacturing Process – Convert the EndEnd

Bubble Button

Form Shell - ProgressionForm Shell - Progression

Manufacturing Process – Convert the Manufacturing Process – Convert the EndEnd

Rehit Score

Form Shell - ProgressionForm Shell - Progression

Manufacturing Process – Convert the Manufacturing Process – Convert the EndEnd

Deboss Inserter

Form Shell - ProgressionForm Shell - Progression

Manufacturing Process – Convert the Manufacturing Process – Convert the EndEnd

Tab Ear Wipedown Incise / Emboss

Converted Converted EndEnd

Manufacturing Process – Convert the Manufacturing Process – Convert the EndEnd

Conversion Info

•9 conversion Presses at RMMC (3-Sys 7, 6-Sys 8)•Press Runs 650 SPM•Plant Constraint Operation•Overall Plant Capacity 15,600 EPM 22,464,000 / Day

Semi – Semi – Auto Auto BaggerBagger

Material Material HandlingHandling

Packaging Info

•3 Pack Types•Small Pack – 198,000 EPP•Secured Pack – 228,000 EPP•Large Pack – 257,400 EPP

Process Quality Process Quality ControlControl

In Line Inspection In Line Inspection SystemsSystems

100 % Camera Inspection of all ends exiting the Liners

Process Quality Process Quality ControlControl

In Line Inspection In Line Inspection SystemsSystems

100% Light Testing for Leaks

Process Quality Process Quality ControlControl

In Line Inspection In Line Inspection SystemsSystems

2% Pressure Test for Leaks

Process Quality Process Quality ControlControl

Off Line Inspection Off Line Inspection SystemsSystems

Offline ColtSPC Pressure Check for Leaks

Process Quality Process Quality ControlControl

Off Line Inspection Off Line Inspection SystemsSystems

SPC Check for Compound Weights

Process Quality Process Quality ControlControl

Off Line Inspection Off Line Inspection SystemsSystems

SPC Check for Tab Strength and Opening Characteristics

Process Quality Process Quality ControlControl

QC LabQC LabFinite End Measurements

Warehouse / Warehouse / ShipShip

Material Material HandlingHandling

Shipment•26 Large Pack Pallets / Trailer – 6,692,400 Ends

Scrap Scrap BailerBailer

Supporting Process – Scrap CollectionSupporting Process – Scrap Collection

PalletizPalletizerer

Supporting Process – Scrap CollectionSupporting Process – Scrap Collection

Bailer / Palletizer Info•Briquettes ~ 40 lbs each•46 Briquettes / Pallet•Generate ~ 3 Pallets / 8 Hour Shift

Tab ScrapTab Scrap

Supporting Process – Scrap CollectionSupporting Process – Scrap Collection

Overall Scrap Recycling

•Total Waste Stream generates ~ $1 Million revenue each month.

Emerging Technology in Emerging Technology in OperationsOperations

24 Out Shell Press with

Stacked Curlers

Emerging Technology in Emerging Technology in OperationsOperations

Advanced Camera System for Finished End

Inspection

Emerging Technology in Emerging Technology in OperationsOperations

Robot arm for bailed scrap

collection

Emerging Technology in Emerging Technology in OperationsOperations

Complete Auto End Bagging

System

Questions ?Questions ?