Documento Mw

Introduction

The PCI Capacity Gap Analysis Model is a diagnostic tool for determining all factors preventing a production line from achieving “standard efficiency”. Specifically the model addresses efficiency loss due to line constraints and filler downtime through an automated analysis on the following key inputs:

Manufacturer’s Rated Speed of Line Equipment
Actual Line Operating SpeedFiller Downtime Data
Scheduled Production Hours
Actual Cases Produced

Tables in the model (input, analysis, look up) are designed to cover a wide range of plant configurations. Items which do not apply are automatically filtered out providing results specific to a given location, package and size.

Line Constraints

The line constraint analysis focuses on the following three key speeds:Filler Rated Speed - Filler manufacturer’s guaranteed speed
Line Rated Speed - Minimum rated speed of all line equipment
Actual Line Speed - Filler speed during normal steady state operations

If the Actual Line Speed is less than the Filler Rated Speed the line is constrained. The cause of this reduction in filler speed can be due to a Design Constraint, an Operational Constraint, or acombination of the two.

A Design Constraint exists any time equipment upstream or downstream of the filler has a manufacturer’s rated speed less than the filler rated speed. In this situation the capacity of the line is limited by line equipment other than the filler.

A Operational Constraint exists any time the Actual Line Speed is less than the Line Rated Speed. The reduction in line speedis normally the result of operational issues such as unstable product, unstable packages, equipment maintenance, operator preference etc.

The model reviews all three speeds and determines if the line is constrained and the magnitude of the constraint.
Introduction (Continued)

Design Constraints

A line with design constraints will run with one of the following Actual Line Speeds.Actual Line Speed is greater than the Line Rated Speed
The filler speed is set above the slowest piece of line equipment.

Actual Line Speed equal to the Line Rated Speed
The filler speed is set equal to the slowest equipment of the line.

Actual Line Speed is less than the Line Rated Speed
The filler speed is set below the slowest equipment of the line.

The most common cause of designconstraints is the installation of equipment upstream and downstream of the filler which cannot support the rated speed of the filler. Best practice speed relationships (between the filler and other line equipment) have been developed to ensure equipment can support filler rated speed and also provide some degree of recovery/accumulation.

These best practice speed relationships are incorporatedinto the model using an automatic look up table to highlight undersized equipment. The lookup table was developed to cover the majority of installations, however if required the Support Center will assist users to modify the table for unique applications.

[pic]
Introduction (Continued)

Filler Downtime

The tracking of reasons and time associated with filler downtime are primary inputsto the model. This continuous effort during a data collection period ensures individual efficiency loss factors are identified. A sample filler downtime collection sheet has been developed and may be used if required. The collection sheet, shown on the next page, contains all the downtime reasons included in the model. Like the look up table this list was developed to cover the majority ofinstallations, however if required, the Support Center will assist users to modify the model’s downtime reason listing to fit unique applications.

The data collection time period is flexible, however to ensure the data is not skewed by isolated events and to understand the effects of seasonality on the manufacturing operation it is recommended that monthly time intervals be used.

Filler...