Issue link: https://www.e-digitaleditions.com/i/238663
d-Davidsonart_16-19_Masters 12/30/13 2:05 PM Page 18 18 January 2014 Tablets & Capsules speed increased by 83 percent, a savings of $365,000 annually. In other words, the costs associated with producing the same number of capsules was greatly reduced because they were produced with less labor, machine time, and associated overhead costs. Improved yield for $94,000 in annual savings. Company B discovered that an excessive number of capsules made using its intermittent-motion capsule filler were poorly joined. The company's inspections required to address the problem caused it to lose production time and lowered yield. During our assessment, we discovered that the setup of the closing station needed improvement: With adjustments to the height of the counter bearing and the timing of the movement, the capsules joined better, resolving the problem. As a result, the inspections became unnecessary, which reduced production downtime, and yields improved by more than 8 percent. In this case, the company saved $94,000 annually on the production of a single product. Reduced downtime for $32,000 in annual savings. Company C was plagued with excessive downtime on one particular product, which had a sticky nature. Because of this product's characteristics, the machine's segments had to be cleaned frequently. Otherwise, the capsules fitting into those segments wouldn't separate. This frequent need to stop and clean resulted in significant delays. After an inspection, we designed and implemented an ejection-brush cleaning system that removed buildup while the machine was running. It greatly reduced the frequency of cleaning and thus downtime, which saved the company $32,000 annually. Increased speed, improved yield, and reduced downtime for nearly $1 million in annual savings. Manufacturer D was receiving a growing number of consumer complaints about bitter-tasting capsules. We discovered that the capsules joined poorly during manufacturing, and the bitter powder was coating segments of the tamping machine, resulting in low yields. A root-cause analysis showed that the sticky and gritty powder used in this product was not being adequately compacted for dosing into the capsule. Thus, to achieve the desired fill weight, operators had set the machine to fill the capsules beyond their capacity. The poorly formed slugs and undersized capsules, however, simply led to greater powder loss, usually into the segment. This interfered with closing the capsules and left residual powder on their exterior, causing the bitter taste. To address this problem, we improved compaction by modifying the equipment to form a better slug and thereby drastically reduced powder losses. As a result, the yield improved by 10 percent; downtime for cleaning decreased; and the speed of the equipment increased by 25 percent without sacrificing weight control. Over the course of a year, savings totaled nearly $1 million and patient complaints dropped drastically. Tracking capsule filling efficiency The goal of our technical service engineers is to unblock customers' paths toward greater efficiency by consulting with them on equipment purchases, product flow, operator training, and equipment adjustments. We're happy to work on whatever areas of capsule filling are holding back the customer from operating better. Still, once improvements are made, it's important to accurately measure the financial gains that follow. Too often, the metrics of performance in the capsule filling room point only to the negative impacts that stem from not following established standards, such as poor yields and frequent downtime. But those metrics don't quantify the business impact, so it's important to calculate the value of improvements. The calculator we use accounts for the sum of all cost drivers, including labor and overhead, to more accurately calculate financial savings. Measuring these cost drivers is a powerful tool for maximizing profits. Table 1 lists the operational factors considered and the results of improvement for the case study that follows. The reports generated by these calculations enable you to justify needed maintenance and to avoid unnecessary costs. They also bring into focus the steps to take to improve the productivity of a capsule filling operation, as the case study illustrates. The loss from defective products far exceeded the cost of replacing the worn segments. Table 1 Efficiency report: Operational data for analysis and results of improvements a. Operational data 280,000,000 315 €75.00 203,000 €150.00 €15.00 0.00 0.0% Unit volume Target fill weight (mg) Fill material cost (kg) Target/rated capsule filling speed Hourly overhead Hourly labor cost Average selling price of finished capsule Estimated markup of finished capsule b. Results of improvement Opening issue Resolved issue Difference Actual capsule filling speed Yield Downtime per 8-hour shift (min) Empty capsule cost (per thousand) 158,981 171,355 12,374 96.1% 29 98.5% 13 2.4% -16 €2.60 €2.60 €0.00 Cost of yield losses Cost of slow capsule filling Cost of downtime Total €301,527 €63,015 €117,996 €42,030 €183,531 €20,985 €17,557 €382,099 €7,302 €167,327 €10,255 €214,772