Discover - Develop - Deliver
Case History
The Problem
One of FES’s customers called to discuss and develop economical solutions to increase their filling and production efficiency for a major Multinational customer. The product is a well-known brand of sports drink powder sold in 51 and 76 oz. composite containers. The problem centered on uptime, labor, poor filling accuracy and speed. Average dual line fill rates were at 22 cpm (51 oz.) with an expected target rate of 75 cpm and weight accuracy outside the acceptable standard deviation specification (51oz. Low: 1435g, Target: 1465g, High: 1495g).
The Solution
FES developed a solution using (2) AS&E’s Portable Servo Auger Fillers with Upstream and Downstream Controls Integration as the current fillers and controls were outdated. The customized controls included a simple, intuitive operator HMI master control section and (2) portable AS&E Servo Auger Fillers which are designed to collect and seamlessly capture a wealth of production perfromance data in real time. This also allows for QA, Production Teams to see instantly where other issues are occurring in their line and get maintenance to resolve.
The Outcome
The AS&E System (fillers, controls) were able to run at 76 cpm, with precise accuracy and ease. However current nominal rates are at 50 cpm as the customer needs to increase product delivery and containers more efficiently to realize this potential. In addition, fillers potential is at 100 cpm. Nonetheless, the outcome exceeded their expectations: Reduced line labor from 6-8 to 2-4 people, uptime efficiency increased from 45 to 90+%, accuracy at +/- 4-5g from target weight, and profitability significantly increased.
About FES
Gary Franger began his start in the industrial Midwest equipment sales industry in 1990; it is truly his passion. During his administration as the Founder & Principal of FES, he developed strategic alliances with manufacturing companies that share his values and a desire to advance their customer’s business. He is also known for his meticulous attention to detail and highly values interpersonal relationships. When he enters a business dialogue, he takes the time to listen, which allows him to offer a range of premier, market value products and packaging machinery services.
An integral part of Gary’s business strategy is facilitating effective communication, which encourages understanding, discovery, and collaboration. He doesn’t always believe in following trends; he strives to solve clients’ issues with creative and innovative practices. Gary has even prompted and led custom vendors to produce speed-to-market solutions using these methods.
