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End Manufacturing at Rocky Mountain Metal Container, with views on emerging technology. Paul Schrock MillerCoors LLC. Rocky Mountain District MBAA Technical Meeting 9/20/2008. What is an End?. - PowerPoint PPT Presentation
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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 ?